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Engineering Process

Control &

MANUFACTURING

INDUS ENGINEERING SERVICES - 69

EMCO - 80

Unlock efficiency with custom control panels tailored to your needs

UNIVERSALTURN 50 - the new benchmark in universal turning

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Global Success Through Innovation Issue 78 2026 £4.95 www.pecm.co.uk

KECOL - 91 The home of food processing pumps, high viscosity pumps and drum emptying pumps

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Engineering Process

Sections

Control &

MANUFACTURING

Inside...

Inside Issue 78

Editor’s Choice

Boilers & Maintenance

Control & Automation

Electrical & Electronics

Facilities Management

Gears, Drives & Motors

Health & Safety

Machining & Machinery

Measurement & Monitoring

Process Technologies

LAMBORGHINI

Automobili Lamborghini renews UNI/ PdR 125:2022 certification for gender equality policies

SWINDON SILICON SYSTEMS

How custom ICs enhance energy efficiency in industrial applications

FAIR FRIEND GROUP

FFG receives major project from India

SOUTHERN MANUFACTURING & ELECTRONICS Visitor registration now open for Southern Manufacturing & Electronics 2026

FANUC

Pumps

Storage, Handling & Distribution

FANUC’s new food/cleanroom robot pairs hygiene with high performance

Tools, Plant & Equipment

INMOCO

Training & Recruitment

109

Exploring linear, rotary, and sine encoders

Valves & Flow Control

110

Cover photo: Wilkinson Star

PORTESCAP

A robust solution for precise motion feedback

NORD

NORD enables virtual commissioning of its drive solutions

MAPAL

Decentralised cooling for maximum effect

ABB

ABB launches new box gauge for aluminum hot rolling mills

BURKERT

ICB Distillers set to reduce production costs with contact-free flow meter

SULZER

Seatrium selects Sulzer’s leading pumps packages for Petrobras P-84 and P-85 FPSOs

“The centre of excellence for strainer and ﬁltraaon technology”

www.bartonﬁrtop.co.uk Issue 78 PECM

GAS PROCESS BURNERS

HMA 2A

Up to 30:1 turndown Up to 205 kW per foot Reduced NO₂/CO Emissions Air replacement or “Make-Up”

FDB Choice of operating fuels Ideal for variable plant conditions Larger heat input available on request APL technology -modulating gas and air

High efficiency Customised design to suit each install Proven in a wide range of applications Choice of burner heat inputs up to 1150 kW FDC Heat input range up to 1,550 kW

FDGA APL technology - modulating gas and air

Choice of operating fuels Packaged burner design Up to 40:1 turndown

Ideal for variable plant conditions Heat input range up to 1,550 kW Choice of operating fuels

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.

BESPOKE DESIGN

FULL RANGE OF INTERNATIONAL ACCREDITATIONS

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

BURNERCARE SERVICE

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

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.

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MANUFACTURING

Control &

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

EDITOR Elizabeth Hutton elizabeth@pecm.co.uk

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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 78 PECM

EDITOR’S CHOICE

RENEWED EQUALITY DRIVE LAMBORGHINI

Automobili Lamborghini renews UNI/PdR 125:2022 certification for gender equality policies The certification, valid for a further three years, confirms the commitment of the Sant’Agata Bolognese-based company to inclusion and equal opportunities Automobili Lamborghini has renewed its commitment to gender equality, inclusion, and equity by obtaining confirmation of the UNI/PdR 125:2022 certification. Promoted by the Italian Government in implementation of Law 162/2021 and issued by DNV, an independent body specialising in assurance and risk management, the certification attests to compliance with the guidelines of the gender equality management system and the measurement of specific KPIs in achieving the objectives. Stephan Winkelmann, Chairman and CEO of Automobili Lamborghini, states: “We are proud to have obtained this certification once again. It is concrete proof of our commitment to promoting gender equality within the company. We strongly believe in policies that make the workplace increasingly inclusive and equitable. This certification does not represent a final goal but rather an incentive to continue along the path we have undertaken.” The confirmation of the UNI/PdR 125:2022 certification, already achieved in 2022, is valid for three years and forms part of a journey that Automobili Lamborghini has been pursuing for some time, within a broader strategy that considers all dimensions of diversity. Specifically, in terms of equal opportunities, in 2019 the company contributed, together

PECM Issue 78

constantly monitors the inclusion of women in its workforce and ensures full equity in internal processes related to access to managerial careers.

Parenthood and work–life balance: pillars of corporate culture with seven other companies from the Bologna area to the creation of the CapoD Network (Community of Companies for Equal Opportunities), established to counter gender stereotypes and promote a culture of gender equality in the Bologna metropolitan area, also encouraging informed orientation towards STEM pathways.

Rising indicators on inclusion and the gender gap The company has long adopted a pay equality monitoring system which currently shows a 0.04% gap in favour of women. The company

Support for parenthood has always been one of the cornerstones of Automobili Lamborghini’s corporate culture. The company promotes a model of balance between private and professional life that guarantees equal rights and protections for mothers and fathers, encouraging shared participation in the care of their children. In this area, Lamborghini has introduced specific support measures, such as the possibility for fathers to request optional parental leave and a protection system dedicated to situations of particular vulnerability, such as single parents or parents of children with disabilities. Between 2022 and today, the proportion of

fathers taking parental leave within the company has risen by more than 10%. The “Dad Coaching” and “Mum Coaching” programmes also continue, providing guidance pathways for new parents that offer training sessions and opportunities for discussion to support a conscious management of the new balance between personal and working life. Among the elements that positively contributed to the confirmation of the UNI/PdR 125:2022 certification is the company’s focus on work–life balance. The recent supplementary contract introduced an innovative restructuring of working hours and significantly increased flexibility, pioneering a redefinition of the balance between production requirements and employee wellbeing. Automobili Lamborghini also confirms the option to make use of smart working for up to 12 days per month.

Learning inclusion through words, behaviours and opportunities Promoting a fair and respectful working environment requires

The company constantly monitors the inclusion of women in its workforce and ensures full equity in internal processes related to access to managerial careers. continuous training and cultural awareness. Over time, Automobili Lamborghini has developed a comprehensive programme comprising both mandatory and voluntary modules on topics such as diversity, inclusion, equal opportunities, conscious language, and unconscious bias, to prevent their impact on everyday interactions and contribute to creating an organisational climate based on respect and collaboration. These initiatives are complemented by specific courses on the prevention of gender-based harassment and workplace bullying,

essential tools for strengthening a corporate culture founded on listening and shared responsibility. Over the year, an important awareness campaign on speak-up culture and the commitment to creating a space based on dialogue and active listening was launched, promoting the respectful reception of feedback and the sharing of ideas and reflections without fear. In 2024 the company also launched an internal communication campaign dedicated to the power of language in creating inclusive environments. Through meetings, editorial content, and moments of dialogue with external guests, the campaign encouraged collective reflection on language as a vehicle for respect and equality. At the heart of the initiative is the “Equabolario”, an inclusive dictionary designed to promote a more equitable and representative vocabulary capable of reflecting the company’s shared values.

Collaborations and community engagement Automobili Lamborghini’s commitment to gender equality and

Issue 78 PECM

inclusion extends beyond company boundaries, through a network of collaborations with institutions, universities, and local organisations. The company is one of the founders of the CapoD Network – Community of Companies for Equal Opportunities – created to promote a culture of inclusion in the Bologna metropolitan area; since 2024, the company has led its activities in the role of President. At the same time, Lamborghini is strengthening its partnership with Valore D, offering all employees free training and awareness-raising initiatives on women’s leadership and the promotion of diversity.

and inspire a new generation of conscious and inclusive professionals.

A daily and widespread commitment For Automobili Lamborghini, the promotion of inclusion is not a series of isolated projects but an everyday commitment involving the entire organisation. Putting people at the

centre means recognising their value, supporting their wellbeing, and creating spaces where everyone can express themselves authentically and contribute to collective growth. In this vision, diversity is a resource, inclusion a concrete objective, and work a place where a more equitable, innovative, and shared future can be built together.

In 2024, together with MUNER – Motor Valley University of Emilia-Romagna – and other companies in the sector, Automobili Lamborghini contributed to creating the Gender and Diversity Empowerment Committee, from which the “MUNER Drives Change” programme was launched. The initiative, aimed at students and teachers, seeks to counter gender stereotypes in the STEM world For further information, please visit www.lamborghini.com

PECM Issue 78

EDITOR’S CHOICE

Fluid Carrying

Flexibility Articulated Torsion Pipework In Hoses Rotating Cylinders

Swivel Joints

THE NEW GEMÜ

FROM

GEMÜ D40

DIAPHRAGM VALVE

GEMÜ 12A0

POSITION INDICATOR

Swivel joints allow pipework to

GEMÜ D41

pressure 1/4” to 40” and beyond.

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Vacuum to over 20,000psi. Stock and bespoke production. Unique bearing/seal design for longer life. ISO 9001 CE marked where applicable.

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GEMÜ S40

MODULAR GLOBE VALVE

New stainless-steel torque limiters for hygiene-critical drives ENEMAC has expanded its portfolio with the fully stainless-steel safety couplings ECWB and ECWD for hygiene-critical drives in food, beverage, and process applications. Their all-stainless construction, including stainless disc springs, ensures resistance to aggressive cleaning and disinfecting agents without coatings and provides full CIP/SIP compatibility. Both models deliver precise, repeatable torque limitation even during automated cleaning and sterilization cycles.

Technical Features • Material: all stainless steel, incl. disc spring pack • ECWB: torque limiter + metal bellows (misalignment compensation) • ECWD: torque limiter + elastomer coupling (vibration damping, plug-in assembly) • Torque range: 5–900 Nm • Shaft diameters: 8–65 mm • Design: particle-free, corrosion-resistant, compact

Scan to learn more:

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.

for hygienic drive systems www.enemac.eu

www.gemu.co.uk

Issue 78 PECM

EDITOR’S CHOICE

NEXT-GEN PERFORATION RMIG SOLUTIONS

Investment in perforation technology provides new options

With a substantial investment, RMIG Solutions increases capacity and provides new options for customers who want to utilise the advantages of premium perforation. For RMIG Solutions, based in Warrington, staying at the forefront of perforation technology is crucial. By providing uncompromising perforation quality and a wide range of choices in materials as well as processing methods, customers experience a partnership that adds value and achieves results. As part of an ambitious investment programme, the UK facilities are being upgraded, including the

installation of a new All Across Press Line featuring a new de-coiler and pre-leveller. The considerable investment underscores the company’s commitment to enhancing the use of premium perforated solutions across various applications. British companies now have access to the most modern technology on the market, combined with over a century of experience and a recognised tradition of innovation. This ensures expert advice and timely results delivered by a highly specialised, skilled workforce at Warrington, the RMIG Solutions hub for UK sales and operations.

The considerable investment underscores the company’s commitment to enhancing the use of premium perforated solutions across various applications.

For further information, please visit rmigsolutions.com

PECM Issue 78

EDITOR’S CHOICE

SMART SEWAGE LIFTING NORTHRIDGE PUMPS

High volume sewage transfer pumps for sewage lifting station A leading construction company overseas faced a critical challenge: safely and efficiently moving large volumes of sewage and sludge water, with a density of around 1,400 kg/m³, for a luxury new-build development. The solution was a sewage lift station at the heart of which sat four high-volume pumps, precisely fitted within a dry well and fed from an adjacent tank.

What is a sewage water lifting station? A sewage water lifting station, also called a lift station or sewage pumping station, is a facility designed to move wastewater uphill when gravity alone isn’t enough. It collects sewage in an underground wet well and, once the wastewater reaches a certain level, automatically activates pumps to push it through pipes to a higher point in the network—often toward a treatment plant. When planning a sewage and wastewater system, choosing the right pump and installation type is critical. Pumps can be submerged in a pit, surface-mounted to prime from a tank, or flooded below or beside a tank. Each choice comes with tradeoffs. Surface-mounted pumps must be self-priming—either by design, as with progressing cavity, peristaltic, or AODD pumps, or specified at the design stage for centrifugal models. While surface-mounted or flooded pumps may cost more upfront, they can reduce long-term maintenance, whereas submerged pumps with motors outside the fluid often require crane removal. Space constraints also play a role: in compact areas like car park chambers, submerged pumps may be the only option.

dual bearings to absorb radial forces, and independent shafts—so only the pump shaft needs replacing if necessary.

Maintenance and reliability are always top priorities. Vertical inline and long-coupled pumps allow insitu servicing, keeping motors safely above the fluid, while safeguards such as liquid detectors and small submersible pumps protect the system against flooding.

Our Solution For this project, we specified four XVIL high-flow vertical inline centrifugal pumps, built for endurance and easy maintenance. Each pump features a spacer coupling,

Each unit handles 180 L/s (650 m³/h), giving a combined capacity of 720 L/s (2,600 m³/h) of sewage. With 10” (250 mm) ports, AISI-316 stainless steel impellers, and 132 kW motors maintaining 3–4 bar pressure, the pumps were paired with three noninvasive electromagnetic flowmeters for 99% flow accuracy. A 162-kW control panel with five multi-contact float switches automatically manages operation based on sewage levels. Installed on a concrete plinth, the pumps stay aligned, reduce pipe strain, allow easier maintenance, and keep intakes clear—ensuring reliable, long-term performance. If you have a project which requires dewatering or simply want a high volume transfer pump in an easy to maintain, low maintenance, reliable unit, speak to North Ridge Pumps to see how we can help.

For further information, please visit www.northridgepumps.com

PECM Issue 78

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

Issue 78 PECM

EDITOR’S CHOICE

A SUSTAINABLE FUTURE SWINDON SILICON SYSTEMS

How custom ICs enhance energy efficiency in industrial applications According to the International Energy Agency, industrial energy consumption makes up nearly one-third of global energy demand. As global nations work towards net-zero targets, reducing energy consumption in manufacturing is critical. However, the growing use of automation and robotics is increasing energy requirements. Here Ross Turnbull, Director of Business Development and Product Engineering at ASIC design and supply specialist Swindon Silicon Systems, explains how ASICs are key to improving energy efficiency in industrial applications.

processing (DSP). As a result, it often executes more operations than necessary, introducing inefficiencies.

As manufacturing becomes increasingly digital, smart factories rely on interconnected systems powered by robotics, sensors and AI-driven machinery. While automation typically improves energy efficiency per unit of production, the greater computational and operational demands of smarter systems can lead to a larger overall energy footprint.

As manufacturing becomes increasingly digital, smart factories rely on interconnected systems powered by robotics, sensors and AIdriven machinery.

The challenges of traditional ICs Integrated circuits (ICs) are essential for key functions in smart factories, including motor control, sensor data processing and machine communication. Off-the-shelf, general-purpose ICs are commonly used in industrial applications due to their costeffectiveness and availability. However, they often prove inefficient in energy-sensitive industrial environments. This is because a standard IC is not fine-tuned for critical industrial functions, such as sensing, performing complex calculations, controlling or digital signal

PECM Issue 78

For example, when processing sensor data or performing DSP tasks like filtering or transformation, a standard IC may take longer to complete computations because it lacks specific optimisation. The prolonged execution time keeps the chip active for extended periods, drawing more power than a custom solution.

Moreover, standard ICs often include additional features and processing capabilities that are irrelevant to the specific application. In sensing applications, for example, a standard IC may execute unnecessary communication protocols or auxiliary data processing that do not directly contribute to the primary function. These additional operations increase power consumption and reduce overall system efficiency. As automation scales up, these inefficiencies compound, leading to greater energy waste and higher operational costs. While individual ICs may not consume large amounts of power, optimising them for low power consumption and high performance is critical for minimising energy waste and lowering operational costs.

A smarter solution Application Specific Integrated Circuits (ASICs) provide a more efficient solution. Unlike general-

purpose ICs, ASICs are engineered for distinct tasks, eliminating unnecessary circuitry and minimising power draw.

benefits. By reducing the number of components and materials needed, ASICs decrease waste generation, lower production costs and support more sustainable manufacturing practices.

For instance, in robotic systems, ASICs can be tailored to refine motor control by optimising pulsewidth modulation (PWM) signals, ensuring motors operate at peak efficiency, improving overall system performance and reducing waste. Furthermore, traditional industrial systems rely on several discrete ICs for signal processing, power management and motor control. However, this increases power consumption, heat generation and overall system complexity. In comparison, ASICs consolidate these functions, reducing energy losses from inter-chip communication and minimising the number of required components. Modern mixed-signal ASICs take this integration further. These chips combine analogue front-end circuits — such as amplifiers, filters and analogue-to-digital (ADC) and

Ross Turnbull, Director of Business Development and Product Engineering at ASIC design

digital-to-analogue (DAC) converters — with digital processing cores to capture, convert and process sensor data in real time. This not only eliminates the need for extra power-hungry components but also enhances signal fidelity, reduces latency and mitigates inter-chip noise. This consolidation has secondary environmental and economic

Swindon Silicon Systems partners with manufacturers throughout the design process —starting from initial specifications to wafer production, packaging and testing. This collaboration ensures that each ASIC is optimised for energy efficiency, functionality and long-term reliability, helping manufacturers meet the operational demands of diverse industrial applications. Integrating custom ASICs into industrial systems is not just about achieving better energy efficiency; it’s about embracing a future where sustainability and performance go hand in hand. ASICs will play a key role in balancing high-performance automation with energy efficiency as industries evolve, paving the way for smarter, greener industrial solutions.

For further information, please visit www.swindonsilicon.com Issue 78 PECM

EDITOR’S CHOICE

A BATCH MADE IN HEAVEN CASTLE PUMPS LTD

Precision batching made simple In the world of manufacturing, precision is everything. You will know how a consistent appearance, performance, taste and texture is vital in meeting your quality standards, reducing waste and protecting your brand with the consumer. Relying on the manual control of transfer is not only putting the burden on your production team (and we all know that time is money!), but also increasing the chance of recipe inaccuracies due to human error. And that is why the accurate transfer of chemicals, process fluids or ingredients combined with the AMP-CONTROL peristaltic pump really is a “batch made in heaven”. Castle Pumps have recently solved two clients’ batching requirements with their AMP-CONTROL peristaltic pump. The first was a manufacturer of low calorie sweeteners looking to batch 10 litres of Glycerin at a time during the production process of their products. The second was involved in the treatment of industrial wastewater and wanted to dose 5-10 litres of ferrous sulphate and caustic soda at a time from an IBC into the water being treated. Both wanted control over the speed at which they could transfer and

component to wear and maintain without risk of seals leaking and valves blocking. The AMP-CONTROL model in particular however had the intelligence to satisfy the companies’ requirements of automation and accuracy without the need for the clients purchasing and installing additional control equipment.

As well as its variable speed drive, the beauty of this pump is that it allows batching to be specified either by volume or by intervals, as well as a calendar for operation automation at set date/ times. the ability to accurately determine how much to transfer in each batch. And that’s when Castle Pumps knew the AMP-CONTROL was the ideal solution. Peristaltic pumps are often used for batching applications thanks to their smooth operation and ability to accurate dose even the smallest volume of fluids at low flow rates. Another huge benefit of the peristaltic design is that with the inner hose being the only wetted part, there is only one

As well as its variable speed drive, the beauty of this pump is that it allows batching to be specified either by volume or by intervals, as well as a calendar for operation automation at set date/times. This peristaltic dosing pump also comes with configurable inputs and outputs that can be used for signal relays to determine when the pump should operate for example when fluid in the receiving container has dropped to a set low level. These benefits allow for highly precise dosing of the additives whilst also freeing up operator time to carry out more value adding tasks. As a fail-safe the AMP-CONTROL also comes with a hose leakage sensor to shut down the pump and alert the operator, as well as a hose replacement alert for preventive maintenance after a set interval to prevent downtime in production. Getting the wrong pump for your process can result in inconsistency in the finished product, crushed solids, clogging, excessive wear, loss of productivity, waste of costly product or at worst, contamination. Always trust technical experts to specify the right pump for your application.

For further information, please visit www.castlepumps.com

PECM Issue 78

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

TURNKEY LINE FOR 60,000 AXLES FFG

FFG receives major project from India MAG IAS GmbH (MAG), a member of the Fair Friend Group (FFG), has received a major order to supply a turnkey production line for railway axles from Jupiter Tatravagonka Railwheel Factory Pvt. Ltd. (JTRWF) in India. The highly automated line is designed for the annual production of 60,000 axles and will be installed at JTRWF’s new plant in Khurda, Odisha. The turnkey solution values in the double-digit million-euros, includes a complete machining and inspection line based on state-ofthe-art manufacturing technology. The core of the system consists of

high-precision VDF Boehringer VDF 450 4T horizontal turning centers and comprehensive automation solutions, including marking and measuring stations, visual final inspection devices, and a central plant control system with endto-end system monitoring and component tracking. “FFG is proud to be part of this pioneering infrastructure project,” explains Dr. Sebastian Schöning, CEO of Fair Friend Group. “Our technological expertise and turnkey solutions make us the ideal partner for JTRWF’s local and international goals – both

in terms of product quality and sustainability.” The entire line is designed for high flexibility and energy efficiency. Four different axle types can be manufactured with minimal changeover effort. MAG relies on a digital plant twin and comprehensive 3D simulations for planning, commissioning, and optimization. Pre-calculated energy consumption in various operating scenarios enables resource-efficient manufacturing. The implementation will take place in close cooperation with the Indian subsidiary MAG IAS India Industrial

MAG IAS GmbH (MAG), a Fair Friend Group (FFG) company, has received a major order from Jupiter Tatravagonka Railwheel Factory Pvt. Ltd. (JTRWF) in India for the turnkey delivery of a production line for railway axles.

PECM Issue 78

Horizontal VDF Boehringer VDF T turning centers enable the economical finishing of railway axles with maximum precision in a single set-up.

Four different axle types can be manufactured with minimal changeover effort. Automation Systems Pvt. Ltd. “With the newly established site in Khurda, we are ensuring that JTRWF receives comprehensive technical support of the highest standard,” emphasizes Shashank M.P., Managing Director of MAG IAS India Industrial Automation Systems Pvt. Ltd. “Our team will support our own brand machines as well as provide service for third-party components.” With this project, MAG once again underscores its role as a leading provider of complex manufacturing systems for the railway industry. The collaboration with JTRWF demonstrates how end-to-end automation, digital planning,

The innovative design of the VDF T series guarantees high productivity at low costs per part and impresses with its reliability, availability, easy maintenance, excellent serviceability, and flexibility

and global service expertise can lead to sustainable solutions in international rail vehicle manufacturing. Approximately 50 percent of production capacity is earmarked for export – a clear signal of the project’s international focus and the site’s competitiveness.

Production start in Khurda is planned for the third quarter of 2026. Until then, MAG will support all steps – from final system integration to the qualification of the on-site operating and maintenance teams.

For more information about FFG visit: www.ffg-ea.com Issue 78 PECM

EDITOR’S CHOICE

TEKNOMEK STRENGTHENS TEAM TEKNOMEK

Teknomek boosts in-house laboratory expertise with new appointment Teknomek, one of the UK’s leading manufacturers and suppliers of hygienic furniture and equipment, has appointed experienced laboratory manager Ricky Williams as head of sector sales. Ricky has spent more than eight years working at a senior role at two of London’s leading life science hubs. From designing laboratory layouts and specifying equipment, to cleaning protocols and earlystage planning and positioning of gasses, pipelines and HVAC systems, he has an in-depth knowledge of the practical and statutory requirements of working labs and cleanrooms. “A significant element of my previous two roles was working closely with scientists and lab technicians to establish efficient and hygienic operational processes,” Ricky explains. “At innovation hubs, start-up businesses are often sharing research and laboratory space. As well as being intelligently designed and perfect for purpose, it’s vital that equipment and furniture is flexible and modular so that workspaces can be reconfigured to suit different project requirements. “Having been a customer of the brand several times over recent years, I already knew the quality of Teknomek’s product range and its bespoke manufacturing capabilities,” Ricky continues. “All laboratory professionals are looking for furniture that has an appropriate resistance to the chemicals used for scientific applications, and those used

I’m here to help customers with layout and design to ensure they end up with a flexible laboratory configuration that supports cleanliness, adaptability and cost-effectiveness for cleaning. They also need to be confident that furniture and equipment provide easy access for cleaning.” Alongside its stainless-steel furniture, which is ideal for cleanrooms, Teknomek has recently launched a new laboratory furniture range with white powder coated frames. “One size definitely does not fit all when it comes to laboratories. Scientists and lab managers need

suppliers who genuinely understand the challenges they are facing. I’m here to help customers with layout and design to ensure they end up with a flexible laboratory configuration that supports cleanliness, adaptability and costeffectiveness,” Ricky concludes. For more information about Teknomek’s range of laboratory furniture and equipment or to arrange a call with Ricky Williams please visit Teknomek.co.uk or email rickyw@teknomek.co.uk.

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

PECM Issue 78

Lab furniture tailored to your needs Introducing Teknomek’s new laboratory furniture that is built for science, backed by compliance.

Flexible Adapt your laboratory as your needs grow with mobile, fixed and sliding cupboards. Ensuring maximum efficiency for changing work processes.

Compliant With Trespa® TopLab Plus worktops and stainless steel options for specialist areas, our solutions are designed to meet relevant EN and GMP standards.

Unique to you We will map out a customised design to suit your workflow that balances practicality with long-term flexibility.

Call 01603 788 833 to arrange your site visit

teknomek.co.uk

EDITOR’S CHOICE

COMPACT POWER BY LINMOT QUIN

High-Speed LinMot Flat Robots at TEAM Automation Berlin TEAM Automation Berlin has developed a high-speed automation machine for a world-leading manufacturer. At the heart of the system: LinMot Flat Robots and Linear Modules – deliver dynamic, multi-axis motion with unmatched precision and flexibility. This machine demonstrates how modular automation solutions set new standards in performance, efficiency, and reliability. Global industry is constantly demanding more. Higher cycle rates, more compact machines, and maximum flexibility with high process stability. While conventional drives are reaching their limits, LinMot’s strengths come into play precisely here, even for the world’s largest manufacturers. The linear modules from LinMot are true all-rounders in the field of automation. Despite their slim design, they are highly rigid and can absorb external forces as well as torsional and bending moments even in the most dynamic applications. This makes them ideal for pick and place and gantry configurations, especially in limited spaces. The modules can be fitted with additional sensors and incorporated

The linear modules from LinMot are true allrounders in the field of automation. into a wide range of machine layouts. To meet even more complex production requirements, the brand new LinMot flat robots offer customizable solutions. In this ready to use system, LinMot drives are combined using the flexible modular system to form multi-axis solutions. This enables even the most complex industry and customer specific requirements to be implemented quickly and precisely in an

extremely compact design with minimal interfering contours. The LinMot motors are all directdrive which provides very high performance and pick-rates in a very small space resulting in a much more compact machine. Conventional actuators also quickly reach their limits when it comes to screwing or sealing, which is why LinMot sets new standards with its linear-rotary motors. Thanks to the decoupled rotary drive, only the motor shaft needs to be accelerated. This keeps the moving mass to a minimum and makes LinMot’s linear rotary motors ideal for precise assembly or screwing even of the smallest work pieces. Talk to our experts. LinMot offers the perfect solution for every application.

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

PECM Issue 78

Linear motors for

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

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

EDITOR’S CHOICE

Versatile Controls Ltd supply high quality stainless steel valves and service to the oil and gas, petrochemical, and process industries. For these industries reliability is essential - only trusted components can be considered. The names of Versa Valves, Ruelco, and ITT are synonymous with dependability. This is how the business started in 1987. These products are on specification with some of the prestigious names in the industry - Shell / BP / Exon Mobil. Visit our website or contact our expert technical sales team for more information. sales@versatilecontrols.co.uk www.versatilecontrols.co.uk

Rising costs drive demand for water recovery systems In today’s manufacturing landscape, water supply limitations, an increase in water charges, and stringent environmental regulations are pressing concerns for industries worldwide. These challenges are driving the adoption of sustainable practices, including exploration into new, more environmentally friendly wastewater treatment solutions. With water shortage fears growing across the UK, companies are re-examining their production processes with a view to reduce the waste of this valuable global resource. “Without a rapid, effective treatment option, liquid effluent can become a costly issue to tackle,” says Jamie George, Projects & Business Development Director at Axium Process. While effluent composition varies with the industry, it is usually composed of microplastics, fats, oils, grease and many other unsavoury particulates. Membrane filtration is able to selectively separate these suspended solids, leaving behind high-quality water that is immediately available for reuse in upstream or downstream processes. Eliminating the need for damaging chemical flocculants, membrane filtration reduces the risk of damage to our rivers and waterways and could potentially reveal the presence of valuable materials that would otherwise be destroyed using alternative methods. Jamie George states “Initial pilot trials on the feed material are carried out, either at our Swansea test facility, or at the manufacturer’s premises. These are instrumental in how we identify and adjust process parameters for optimal filtration results.”

Able to provide a reliable, cost-effective solution to reducing discharge volumes with the potential to recovering up to 90% of wastewater, membrane filtration is a tried-and-true solution for water recovery needs. Plants can be constructed in a variety of setups, from containerised units to small, compact systems that can be moved to other areas as needed and can also be designed with future expansion in mind. Axium’s extensive expertise allows for the design and manufacture of crossflow membrane filtration solutions tailored for diverse applications, all while adhering to international regulations and maintaining the highest of hygienic standards.

For further information, please visit www.axiumproces.com

PECM Issue 78

EDITOR’S CHOICE

news

Steam trapped?

Zeus Packaging Group acquires Simpac Promptly identify steam trap

Zeus Packaging Group, the global packaging company, has acquired Simpac Limited, the paper sack and packaging manufacturer. Founded in 1903, Simpac has established itself as a market leader in fibre-based packaging, supplying bespoke paper sacks, branded food wraps, carrier bags, and ⦿ e-commerce Simple - Quickly installed on any type of steam trap sustainable Sandy Bole, managing director of Simpac, mailers to some of the Brian-O’Sullivan, owner & founder of Zeus ⦿ Cost High return on investment through loss reduction UK’s largest retailers,effective food Group, Luke Cobbett, operations & businesses, and production director of Simpac ⦿ producers. Zero maintenance - Battery-free energy harvesting eliminates changes agricultural Operating from facilities in Hull and Glasgow with over 130 employees, Simpac⦿ generates exceeding £30 million. Liverevenues (real-time) data - Real-time temperature, acoustic, vibration, ... By joining forces, Zeus customers gain access to Simpac’s specialised manufacturing expertise next-generation sustainable products,solution while ⦿and Turn-key - End-to-end with no site IT requirements Simpac’s customers benefit from Zeus’ European supply chain infrastructure, global procurement strength, and advanced manufacturing capabilities across corrugated packaging, film extrusion, tapes and labels, and retail bag production.

leaks and faults with

real-time trap monitoring

solutions. Fast deployment from a pilot through to site.

t: 01285 359059 | e: sales@dcosystems.co.uk w: www.dcosystems.co.uk

Damm opens first brewery outside the Iberian Peninsula

Spanish brewing business, Damm has officially opened its first brewery outside the Iberian Peninsula – The Damm Eagle Brewery in Bedford, England. Strategically located between London and Birmingham, the site ensures efficient logistics while aligning with the group’s sustainability goals. Since 2010, AI Engineering project, whether Since acquiring the historic brewery in 2022, Damm has invested more been at the forefront of for automotive, than has £70m in a complete modernisation featuring a state-of-the-art canning precision CNC machining — manufacturing line, an additional brewstream, almost doubling capacity to or 1.8food-andmillion combining craftsmanship, drink industries, is completed hectolitres per year, with a target of 2 million by 2027. cutting-edge technology exacting standards. Jorge Villavecchia, managing director ofwith Damm, said: “Our commitment ISO capital 9001 certification goesand beyond investment. We are bringing innovation and aAI Clientsskills, consistently praise ideas into visiontooftransform how industry must evolve to remain competitive: reliable more digital, more Engineering’s service, reality. more Based in Dumfries, sustainable, resilient. competitive pricing and AI Engineering specialises in again, its ability to adapt and emerge “This country has shown, time and flexibility. CNCfrom milling, turning, stronger adversity. That rapid is why we believe that our decision to invest in Bedford will contribute only to Damm’s growth, but also to the resilience prototyping andnot subcontract From concept to finished of the UK’s wider delivering economy.” machining,

Precision engineered to perform

brings precision, professionalism and passion

To advertise your services on the news pages contact us on 01472 310302 With a team of experienced engineers using advanced CAD/CAM software, their dedication to quality and innovation ensures that each

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— turning your designs into high-quality machined

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bespoke parts precisely to your specifications.

component, AI Engineering

NEW HIGH PERFORMANCE COMPRESSED AIR HEATERS

Designed for operating pressures up to 6 bar

Reinforced housing engineered to withstand high-pressure conditions

Modular design for a wide range of adapters

Space-saving design ideal for compact systems with limited space Easily adapted to many industrial processes - packaging, food processing, automotive manufacturing, tube production

solutions built to perform. www.aieng.co.uk

Tel: +44 (0)1707 331111 | info@welwyntoolgroup.co.uk | www.welwyntoolgroup.com

Food & Drink International 9 Issue 78 PECM

SHOW PREVIEW

ENGINEERING EXCELLENCE SOUTHERN MANUFACTURING & ELECTRONICS

Visitor registration now open for Southern Manufacturing & Electronics 2026 Visitor registration is now open for Southern Manufacturing & Electronics 2026, the South of England’s leading annual event for engineering and electronics professionals. Taking place from February 3–5, 2026 at the Farnborough International Exhibition Centre, the show marks its 28th year as a key meeting point for the UK’s industrial community. Celebrated for its heritage and distinctly British character, Southern Manufacturing & Electronics continues to attract engineers, designers, manufacturers and innovators from every corner of the UK. Its strong domestic following is complemented by growing international interest, offering overseas exhibitors and visitors a valuable opportunity to engage with the UK market and strengthen sovereign supply chains. The event is home to the largest electronics trade show in the UK, showcasing the full breadth of the electronics supply chain. From components, PCBs and semiconductors to test & measurement solutions, design services and advanced manufacturing technologies, the show provides an unrivalled platform for discovering innovations, sourcing new suppliers and connecting with industry specialists. Now part of the Easyfairs portfolio, one of the world’s top 20 exhibition organisers, the event will retain its core identity while benefiting from Easyfairs’ digital expertise

and extensive industry networks. Exhibitor demand is stronger than ever, with the 2026 edition already close to full capacity, reinforcing the show’s reputation as the UK’s premier marketplace for manufacturing and electronics innovation. Visitors and exhibitors will also gain access to Easyfairs’ event app and smart badge technology, enabling seamless information exchange and helping participants maximise the value of every interaction. A number of popular features return for 2026, including the Global Electronics Association’s Soldering Competition. New for this year is the Wire Harness Competition, set to draw significant interest with its focus on practical technical skill. Two dedicated seminar theatres, one for Manufacturing and one

for Electronics, will host a full programme of CPD-accredited presentations. Expert speakers will share actionable insights on improving production efficiency, strengthening digital capabilities and unlocking opportunities for business growth. Attendees will gain practical guidance on integrating digital tools and systems to enhance productivity and long-term competitiveness. “Southern Manufacturing & Electronics has been the beating heart of the UK’s engineering calendar for nearly three decades,” said Simon Farnfield, Event Director at Southern Manufacturing & Electronics. “We’re committed to preserving what people love about the show while introducing smart tools that deliver even greater value. We look forward to welcoming the community back to Farnborough in February.”

Free visitor registration is now open. Secure your place at register.visitcloud.com/

PECM Issue 78

The Heart of British Manufacturing & Electronics

10000+ attendees

years as the South’s leading industry show

Start your year in 2026 at Southern Manufacturing & Electronics - the nation’s favourite industrial event and the essential meeting point for the South’s manufacturing and electronics communities.

Bringing together over 550 suppliers, from global giants to agile SMEs, the UK’s leading trade show offers a complete view of the supply chain in one dynamic marketplace.

550+ exhibitors

As the ﬁrst major industrial event of the year, Southern is your opportunity to stay ahead of the curve, connect with key partners, and drive projects forward, for a successful year of innovation and growth.

“I’ve found it incredibly useful - great for sparking new ideas and making valuable contacts. It’s exciting to discover a wide range of technologies and products I hadn’t come across before. It’s an excellent way to stay up to date with the latest industry trends. The event is massive, with so much to see. I’d deﬁnitely recommend attending, and I’m really looking forward to the seminars!” Peter Bates, Design Engineer, Rolls-Royce

Visit the website

southern@easyfairs.com +44 (0)20 3196 4414

BOILERS & MAINTENANCE

FULL-SPECTRUM BOILERS BABCOCK WANSON

Babcock Wanson extends range to large shell boilers & heat recovery steam generators for high demand applications

Babcock Wanson UK, a leading supplier of industrial process heating equipment and solutions, has announced the extension of its product portfolio to encompass large high pressure firetube boilers up to 50barg and output to 70 t/h and watertube boilers up to 90barg and 150t/h, along with heat recovery steam generators (HRSGs), making it the only company in the UK capable of providing the complete spectrum of industrial boiler solutions — from compact coil type steam generators through to large, high output watertube systems. The addition of large-scale boiler systems designed for the most

PECM Issue 78

demanding industrial applications has been brought about through the integration of German company VKK Standardkessel into the Babcock Wanson Group. The full VKK range is now available through Babcock Wanson UK, supported by its renowned local service and engineering expertise. By offering VKK Standardkessel boilers in the UK, Babcock Wanson UK brings together advanced German engineering with its own proven capability for total system design, local project management, and after-sales service. Customers benefit not only from tailor-made, high-capacity boiler technology but also from Babcock Wanson

UK’s on-the-ground expertise in installation, commissioning, UK regulatory compliance and maintenance. The VKK product portfolio available through Babcock Wanson UK covers a wide range of industrial energy needs. It includes single and double flame watertube boilers, hot water boilers, highpressure steam generators with or without superheaters, and HRSGs for combined heat and power applications. The unique Condor range combines watertube and firetube technology to deliver high pressure, low emissions and superheated steam from a

compact, highly efficient design. Capacities range from 2 to 70 tonnes of steam per hour, with operating pressures up to 38 bar and steam temperatures up to 450°C, while hot water boilers can be supplied up to 50 MW and 30 bar. The Condor range is also available for electrical and hybrid operation, enabling industries to prepare for the energy transition and make use of surplus renewable electricity. Hybrid Condor boilers incorporate flanged electric heaters alongside traditional combustion to reduce CO2 emissions, operate flexibly according to fuel pricing, and provide additional standby capacity. VKK’s full-electric Condor boilers are available up to 11 MW, offering more than 99% efficiency and a practical route to zero-emission steam and hot water. VKK HRSGs provide an effective solution for utilising waste heat from gas turbines, CHP plants and

These robust HRSG systems can be supplied with auxiliary firing for additional steam output and are engineered for high availability, flexibility under load changes, and long service life.

The VKK product portfolio available through Babcock Wanson UK covers a wide range of industrial energy needs. industrial processes, ensuring both improved energy efficiency and reduced environmental impact.

“The addition of VKK Standardkessel boilers and HRSGs significantly broadens Babcock Wanson UK’s portfolio, making it unique in the UK for its capability to supply and support both firetube and watertube boilers up to the highest output levels” states Etienne Fourie, Technical Sales Manager for Babcock Wanson UK’s Process Engineering Division. “This positions us as the partner of choice for customers looking for energy efficiency, reliability, and a full lifecycle approach to boiler house operations.” For more information, please contact Babcock Wanson on 020 8953 7111 or info@babcock-wanson.com or go to www.babcock-wanson.com

For further information, please visit www.babcock-wanson.com Issue 78 PECM

CONTROL & AUTOMATION

SMART EMISSIONS TECH CODEL

Introducing CODEL’s game-changing triboelectric dust monitor range In an era where environmental regulations are tightening and industrial efficiency is non-negotiable, CODEL has launched a trio of triboelectric dust monitors tailored to meet diverse compliance and operational needs with precision and reliability.

A range engineered for precision and performance Available now, CODEL’s Triboelectric Dust Monitor Range comprises three model families: • DCEM 6000 A premier, QAL1-certified analyser designed for continuous emissions monitoring. It meets the stringent EN 14181 and EN 15267-3 standards, delivering exceptional accuracy and sensitivity for processes where regulatory compliance is critical. • EnergyTech 600 Series (including ET 600 and ET 610) A versatile mid-range option certified to EN 15859, offering real-time particulate measurement for balanced compliance and operational insight. ET 600 excels as a dust monitor, while ET 610 is optimized for early-stage filter leak detection, ideal for process control across power generation, cement, chemical, and manufacturing sectors. • EnergyTech 300 Series A cost-effective solution built for burst bag detection in dust extraction

A launch met with excitement and momentum

CODEL’s Triboelectric Dust Monitor Range marks a significant leap forward in the field of emissions and filtration monitoring. systems, offering fast, reliable alerts in applications such as woodworking, mineral processing, and bulk material handling.

The Advantage of Triboelectric Technology What sets this range apart is the proven triboelectric sensing method, known for its robustness, minimal maintenance, and accurate, real-time readings. Unlike optical devices susceptible to alignment issues, humidity, or soot, triboelectric monitors deliver dependable performance even in harsh industrial environments.

Smart, connected monitoring with CODEL Cloud Each monitor in the Triboelectric Range integrates seamlessly with CODEL Cloud, a centralized digital hub for real-time data, reporting, and analytics. This connectivity enables proactive maintenance, enhanced compliance tracking, and improved filtration efficiency, all accessible remotely and securely.

CODEL officially unveiled the Triboelectric Range earlier this year and received an overwhelmingly positive response from both customers and distributors. Industry feedback praised the range’s versatility, accuracy, and costeffectiveness, especially in reducing operational downtime.

Why it matters to industry • Compliance without Compromise: Whether the project demands high-level regulatory monitoring or practical filter control, there’s a model tailored to deliver precision under the relevant standards. • Operational Efficiency: Access to real-time data through CODEL Cloud, issues can be addressed before escalation, reducing maintenance costs and retaining uptime. • Future-Proofing: Built with scalability and adaptability in mind, the Triboelectric Range supports evolving environmental standards and industry expectations.

Final thoughts CODEL’s Triboelectric Dust Monitor Range marks a significant leap forward in the field of emissions and filtration monitoring. By pairing high-performance triboelectric sensing with innovative cloud integration, CODEL offers industrial operators agile solutions that are both future-ready and firmly aligned with regulatory demands.

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

PECM Issue 78

Triboelectric

A Forbes Marshall Company

New

Dust Monitoring

Minimise Downtime, Maximise Profits, Stay Compliant CODEL Triboelectric Dust Monitor Range

DCEM 6000 QAL 1 Dust Analyser

EnergyTech 600 Series Certified Dust / Filter Leak Monitor

EnergyTech 300 Broken Bag Detector

Get Connected! Realtime Data, Alarms and Reports.

Your Partner in Dust Management Accurate and Affordable Dust Monitoring Solutions

CODEL’s comprehensive range of triboelectric dust monitors is designed to meet every level of industrial emissions monitoring. Whether you need simple, cost-effective burst bag detection or a high-precision QAL1-certified analyser for regulatory compliance, CODEL has a solution tailored to your application.

DCEM 6000 - Certified to EN 14181 & EN 15267-3 (QAL1) 0-7.5mg/m3

EnergyTech 600/610 - Certified to EN15859 with mg/m3 output available. EnergyTech 300 - Affordable solution for burst bag detection.

Triboelectric sensor technology, proven method for accurate dust detection. Direct sensing method, actual particulate concentration. Easy installation with minimal maintenance required. Compatible with CODEL Cloud, online real time data platform.

Scan for more

Ideal for monitoring dust within…

Industrial Manufacturing, Power Plants, Cement Plants, Dust Collectors, Chemical Manufacturing, Mining Operations, Woodworking and Sawmills, Waste Management, Recycling Plants, Power Generation, Pharmaceutical, Construction Sites

For more information and full specification

www.codel.co.uk - sales@codel.co.uk - +44 (0) 1629 814351

CONTROL & AUTOMATION

THE HIDDEN VARIABLE GEMINI DATA LOGGERS

Why thermal mapping matters in modern industrial facilities In today’s manufacturing and process engineering environments, temperature stability is a critical factor that directly influences product quality, equipment reliability and operational efficiency. Yet large industrial facilities such as warehouses, production halls, plant rooms and automated lines, often face complex thermal behaviour that standard HVAC systems cannot fully control. Warm air stratifies in tall buildings, localised heat loads distort airflow and external weather fluctuations introduce unpredictable variations. For operators working in sectors where consistency is essential, from precision engineering to materials processing and controlled storage, this creates a problem: conditions can appear stable on paper while hiding variations that undermine performance. This is where thermal mapping becomes invaluable.

Understanding the True Thermal Behaviour of Your Facility Thermal mapping is the process of placing a network of data loggers across a defined space to measure how temperature behaves over time. Unlike single-point monitoring, mapping creates a complete picture, revealing hot and cold zones, temperature-related uneven airflow, and the influence of machinery or structural features. These insights help engineering teams: • Confirm that controlled environments perform as intended

Tinytag Temperature Mapping: A Proven, Reliable Approach Tinytag by Gemini Data Loggers has been manufacturing robust, highaccuracy environmental monitoring instruments for over 40 years. Our data loggers are used worldwide to support environmental control in demanding industrial environments.

• Identify areas where temperature instability could affect product quality • Validate HVAC performance and guide corrective actions • Understand seasonal variation and its impact on operations For industries handling temperaturesensitive materials, operating curing or bonding processes or storing highvalue or perishable inventory, this level of assurance is essential.

A Practical Tool for Commissioning, Validation and Improvement Thermal mapping is increasingly used as part of facility commissioning, system upgrades and engineering validation. While not always mandated, it provides evidence-based confidence that environmental controls are fit for purpose. Mapping studies often uncover issues that routine monitoring cannot detect such as air stagnation behind equipment, temperature layering near ceilings or inconsistent cooling across racking.

For operators requiring full thermal mapping studies, Tinytag works with specialist partner Valcomm to deliver comprehensive services including multi-point data collection, analysis and full documentation. Guided mapping kits are also available for teams wishing to complete studies internally using their own personnel.

Turning Insight into Operational Advantage Whether used for compliance, process optimisation or engineering assurance, thermal mapping gives industrial facilities the clarity needed to operate with confidence. By understanding exactly how temperature behaves, teams can strengthen reliability, improve efficiency and protect product quality across their operation.

This makes mapping a valuable tool for engineers seeking to reduce risk, optimise performance and support data-backed decision-making.

For further information, please visit www.geminidataloggers.com

PECM Issue 78

EnvironmentalIntelligence. Intelligence. Environmental

Engineered for for Industry. Industry. Engineered THERMALMAPPING MAPPING&&ENVIRONMENTAL ENVIRONMENTAL THERMAL MONITORINGWITH WITHTINYTAG TINYTAG MONITORING

GatheringQuality QualityData Dataforfor4040Years Years Gathering 9Identifyenvironmental environmentalrisks riskstotoprotect protectequipment, equipment,processes processesand andproduct productquality. quality. 9Identify

Startmapping mappingthethe Start invisibletoday... today... invisible

9Validatetemperature temperaturebehaviour behaviouracross acrosscomplex complexfacilities. facilities. 9Validate 9OptimiseHVAC HVACand andenergy energyperformance performancewith withreal-time real-timeenvironmental environmentaldata. data. 9Optimise Tinytag delivers the reliable environmental insight that industrial sites depend on. Tinytag delivers the reliable environmental insight that industrial sites depend on. Our British-made data loggers and thermal mapping solutions provide engineers Our British-made data loggers and thermal mapping solutions provide engineers with the accuracy, visibility and confidence needed maintain stable conditions, with the accuracy, visibility and confidence needed toto maintain stable conditions,

+44 1243 813000 +44 (0)(0) 1243 813000

reduce operational risk and optimise energy performance across demanding reduce operational risk and optimise energy performance across demanding

sales@geminidataloggers.com sales@geminidataloggers.com

industrial environments. industrial environments.

www.geminidataloggers.com www.geminidataloggers.com

geminidataloggers.com/thermal-mapping geminidataloggers.com/thermal-mapping BRITISH DESIGN & MANUFACTURE BRITISH DESIGN & MANUFACTURE

9001:2015 BSBS ENEN ISOISO 9001:2015 Picture illustration purposes only Picture for for illustration purposes only

14001:2015. BSBS ENEN ISOISO 14001:2015.

CONTROL & AUTOMATION

FANUC DEBUTS LR MATE FANUC

FANUC’s new food/cleanroom robot pairs hygiene with high performance To meet the growing demand for food and cleanroom applications, FANUC has unveiled the latest model in its LR Mate industrial robot range. The compact and powerful LR Mate 10-11A Food/Clean has a 10kg payload and is compliant with ISO 4 Class cleanrooms, making it ideal for use in highly controlled environments across sectors such as medical device manufacture, pharmaceutical, biotech, semiconductor, electronics, optics and laser. Its use of foodgrade lubricant means it also meets strict food environment requirements, minimising the risk of contamination in the event of accidental contact with food to aid public safety and prevent costly product recalls. The LR Mate 10-11A Food/Clean robot can withstand harsh and frequent washdown procedures thanks to IP67 ingress protection rating across its entire body, upper arm and wrist. Further benefits include a stainless steel flange, antirust bolts and a special corrosionresistant white epoxy coating. Optimised for high-speed operation, it boasts speeds of up to 340°/s in the J3 axis (upper arm) and 800°/s in the J6 axis (wrist rotation). Designed to save space in busy production environments, the new FANUC model features universal mounting capability (floor, angle, upside down), while the electrical harness is completely integrated within the arm to minimise interference with peripheral devices and allow the construction of smaller automated cells. This

It’s a powerful performer with a small footprint, making it perfect for expensive floor space facilities such as cleanrooms. design also supports easier cleaning and maintenance, underpinned by FANUC’s renowned lifetime spare parts availability. Fully integrated solenoid valves to open and close the gripper means no additional installation is necessary, saving time and supporting plugand-play operation – simply connect the robot to a standard single-phase electricity supply and a compressed air source to start using it instantly via the FANUC Teach Pendant.

“The LR Mate 10-11A Food/Clean with its 10kg payload bridges the gap between our small 7 kg payload version and larger models starting at 25kg payload,” explains Paul Ribus, FANUC’s Head of Sales Coordination Europe. “It’s a powerful performer with a small footprint, making it perfect for expensive floor space facilities such as cleanrooms. In addition, our new robot is ideal for buildings with a low ceiling height, while a 13kg high-payload mode is optionally available, with a reduction in reach.” Offering a new era of powerful performance, the LR Mate 10-11A Food/Clean comes with FANUC’s new R-50iA controller as standard, along with intelligent features, advanced cybersecurity and the potential to provide energy savings. In addition, the robot provides vision-ready precision, ideal for high-speed, vision-based pick-andplace tasks, for example.

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

PECM Issue 78

NEW COMMAND & SIGNALLING DEVICES FOR FOOD PROCESSING: SANITATION MEETS INNOVATION Schmersal now offers a complete range of innovative command and signalling devices specifically designed for hygiene-sensitive environments in the food processing industry. Engineered for maximum cleanliness and reliability, these devices feature seamless transitions between sealing elements and surfaces, no protruding parts makes them exceptionally easy to clean. Their robust design withstands high-pressure washdowns and aggressive cleaning agents, meeting the highest hygiene standards. With 147 device options available including mushroom pushbuttons, selector switches, and potentiometer-rotary switches you have the freedom to configure your control panels exactly how you need them. Whether you are upgrading existing systems or building new equipment, this range offers the flexibility to design a safe and hygienic human-machine interface that fits your exact requirements. For added customisation, all devices can be supplied with individual laser marking, including your company logo.

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

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

CONTROL & AUTOMATION RADIO TELEMETRY MEASURE - MONITOR - REPORT PROTECT - CONTROL

INDUSTRIAL DATACOMMS SOLUTIONS

Blown-up RS485 interfaces? Use KK isolated converters...

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Distances from meters to tens of km, cyber secure non-IP protocol, no SIM cards. Point-to-point, simplex or half duplex, with gateways to interface to BMS and SCADA. 100% autonomous in operation over a billion messages already delivered annually. Backed up with a team with over 40-years sector experience.

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Kit encoder with incremental or PWM output The Hall effect encoder kit from MEGATRON’s MKI series offers a resolution of 1 to 8,192 pulses per revolution (12 bits with PWM) and can be easily fitted in even the tightest spaces. Its compact design and low power consumption make this single-turn encoder the ideal angle sensor for autonomous systems. Since the rotary encoder has no bearings, it has an unlimited mechanical service life. The MKI series kit encoder from MEGATRON gives engineers extreme flexibility in their design work. This rotary encoder has a housing diameter of just 14.8 mm and a depth of only 21.4 mm, making it suitable for shafts with diameters ranging from 3 mm to 6.35 mm. Other features include a wide input voltage range of up to 16.5 V and low current consumption of 17 mA (without load). Additionally, the rotary encoder utilises the application’s shaft, making it mechanically wear-free and maintenance-free. This is particularly advantageous for mobile applications or those involving high speeds, where sleeve or ball bearings cannot be used or would quickly wear out.

The MKI consists of a sensor housing and a mounting ring, as well as a slip-on magnet that matches the shaft. It has an incremental output and can also be supplied with a PWM signal. Thanks to

www.megatron.de/en/

PECM Issue 78

the integrated Molex plug connection, the signal cable can easily be connected to the evaluation unit during installation or disconnected from the application during maintenance work.

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ELECTRICAL & ELECTRONICS

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Electronic Design & Engineering We offer PCB schematic and layout design including advanced multi-layer and HDI boards, combined with NPI support, DFM reviews, thermal and signal integrity analysis. Our designs are tailored for reliable manufacturability and long-term supply security.

PCB Manufacturing Arrival Electronics combine technical expertise with a global manufacturing network to deliver high-quality, cost-effective PCBs both from the UK and offshore. From simple double sided to complex HDI, Flex and Flex Rigid PCB’s, we deliver on time to customers exact specifications from quick turn prototypes through to serial volume.

PCB Assembly We support high-technology contract manufacturing projects including complex

PCB assembly, system integration, and box build services. We handle prototype and pre-production builds through to serial production for market sectors such as aerospace, security, defence, medical, industrial, and communications. AS9120B accredited and our manufacturing capabilities include ISO13485, TS16949 and AS9100.

Electronic Component Kitting We offer tailored kitting solutions that consolidate multiple components into ready-to-assemble kits, streamlining your production process, reducing procurement workload, and improving build efficiency.

www.arrivalelectronics.co.uk | sales@arrivalelectronics.co.uk

Issue 78 PECM

ELECTRICAL & ELECTRONICS

FEEDBACK DEVICES INMOCO

Exploring linear, rotary, and sine encoders

Encoders are the most widely applicable feedback devices for high-precision industrial servo systems.

Encoders are the most widely used feedback devices for electric motor control, capable of delivering precise position and speed feedback for closed-loop performance. With numerous technology options to choose from, selection of the right encoder technology is critical. Gerard Bush, engineering advisor at motion specialist INMOCO, discusses the technology behind incremental encoders. In a recent article, we looked at the uses of Hall effect sensors and resolvers for the control of electric motors. Due to the design requirements of Hall effect sensors and resolvers, they are both are

PECM Issue 78

usually integrated with the design of the motor to achieve commutation feedback and provide closed-loop feedback respectively in extreme environments. However, the most common feedback device is the encoder, providing accurate position and speed sensing. Available in a range of designs according to the motion control requirement, encoders are typically selected following, and in addition to, the specification of the motor. The variety of encoder designs available means that careful attention is required to their selection, and the initial factor is their physical measurements.

Rotary or linear encoder? A rotary encoder measures the angular rotation of the motor’s rotor or shaft. This lends itself to closed-loop control for rotational applications, from a robotic limb, through to a spinning machine tool. To achieve this, the signals from its sensors are converted into digital pulses or sine/cosine waveforms, which the drive or controller interprets for speed and position management. Alternatively, a linear encoder can be preferable for applications that involve a straight-line of operation, such as a CNC machine or three-axis gantry. A linear encoder directly measures true linear position, while

a rotary encoder interprets linear travel by converting shaft rotation. The difference is that factors such as mechanical compliance or backlash can affect the reading of the rotary encoder. For straightline applications that demand the very highest-speed operation, or precision down to resolutions of 0.1 μm (micron) or less, a linear encoder is optimal.

Optical and magnetic encoders The primary ways an encoder can read changes in speed or position is by optical or magnetic means. Magnetic encoders detect changes in a magnetic field according to rotational or linear motion, with the variations converted into signals that provide position and speed information. As the presence of dust or moisture doesn’t interfere with this measurement, combined with an inherently robust sensor design, a magnetic encoder is durable in tough environments. Alternatively, optical encoders comprise a light source, a rotating code disc or linear scale divided into lines, and a light detector. This technique achieves greater precision compared to the magnetic principle as the light sensors can detect a higher number of counts compared to magnetic field changes, which are limited by pole spacing. Optical encoders are also immune to high-noise or electromagnetic interference that could interfere with clean signals and distort data transmission. While modern optical encoders feature better-protected electronics and optics, improving their resilience for lighter industrial applications, magnetic designs, or resolvers, could be better suited to the most demanding environments.

Optical encoder operating principles On an optical encoder, the disc or linear scale is divided into a quantity of lines that signify the encoder’s resolution. As the count increases, the accuracy within a specific number of counts increases as well.

With numerous technology options to choose from, selection of the right encoder technology is critical. Taking a rotary encoder, as the disc rotates, the light detector registers the on-off pattern of light passing through it, which the photodiode detector converts into a digital signal. The disc features two rows of lines, offset by half their width or a quarter of a complete cycle (90 electrical degrees). This generates two electrical signals known as Channel A and Channel B. The role of the offset enables the drive or controller to determine the direction of the shaft rotation. Additional channels can help track shaft position and homing as well as helping with noise immunity. This is the operating principle of an incremental encoder, which provides positional information relative to its starting point. An incremental encoder’s resolution can be multiplied by four if the counting circuit monitors both the rising and falling edges of Channels A and B, a process known as quadrature detection. Higher resolution improves repeatability and enables faster, higher accuracy control loops. Encoder resolutions up to 5,000 lines per revolution are standard, although line counts up to 100,000 are available.

Sine encoders When Channels A and B of an incremental encoder are output as square waves, the drive or controller reads the edges directly. Instead, it’s possible to read these signals as sine waves, enabling much finer gradations of measurement. This increases resolution and reduces truncation errors, ultimately enabling higher loop gains. As a

result, sine encoders can achieve over two million counts per revolution. Thanks to this capability, sine encoders are intended for applications that demand the highest levels of precision, ranging from high-speed registration to film coating and web control. These designs of encoder also a fit lowspeed operations that demand smooth motion control. Thanks to their capabilities, sine encoders can also be used when absolute, rather than relative position sensing, is required – more on absolute versus incremental sensing in the following article. For assistance selecting the encoder technology to optimise your application, contact INMOCO’s engineers. Supplying feedback technology from reliable brands including Kollmorgen, INMOCO offers objective advice on motion design, backed up by years of examples installed in the field.

About Kollmorgen Kollmorgen has more than 100 years of motion experience, proven in the industry’s highest-performing, most reliable motors, drives, linear actuators, gearheads, AGV control solutions and automation platforms. Kollmorgen delivers breakthrough solutions that are unmatched in performance, reliability, and ease of use, giving machine builders an irrefutable marketplace advantage.

About INMOCO Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customerspecified electro-mechanical development and sub- assembly services; including calibrating and testing in a class 10,000 clean room facility.

For further information, please visit inmoco.co.uk | www.kollmorgen.com Issue 78 PECM

ELECTRICAL & ELECTRONICS

MEASURE WITH CONFIDENCE LABFACILITY

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. To sustain longevity, you have to evolve...

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For further information, please visit www.labfacility.com

PECM Issue 78

TEMPERATURE & PROCESS TECHNOLOGY

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ELECTRICAL & ELECTRONICS

CABLES BUILT TO LAST ELMERIDGE

Low Voltage (LV) Cables From Elmeridge Elmeridge Cables Limited (Elmeridge) have been leaders in the production and distribution of custom-made cables since 1987, supplying a wide range of low, medium and high voltage special cables and stock items to a growing worldwide market. Our low voltage custom made cables are used across a variety of sectors, including: Aerostat (TARS) Airports & Aviation CCTV Mainline (Pipes & Drains) Cranes & Lifts Fish Farms & Fisheries High Temp & Thermocouples Instrumentation & Control Medical & Science Military Defence Mines & Quarries Nuclear Energy Oil & Gas Pumps & Sensors Railways & Trams Renewable Energy Robotics & Automation Satellites & Aerospace Underwater Marine & Offshore For almost four decades Elmeridge have built a reputation for designing, producing and distributing low voltage custom made cables. Here are just a few examples, with a brief description and background context: Polyurethane Cable - We provided our polyurethane cable to a North Sea fish farm. Fifteen years later we got a call to say that the cable had failed. However, after close inspection we found it was in fact the connector that had failed, not the cable. Needless to say, the cable was placed back into operation with a new connector, and as far as we know it is still in use today, more

PECM Issue 78

than 20 years later. Our Supreme Polyurethane compound is widely used by numerous underwater marine and offshore companies thanks to its superior properties. It is hydrolysis, UV, and abrasion resistant, offering robust durability under challenging conditions. Despite its toughness, the compound retains flexibility and is available in a range of colours.

Divers Communication Cable Blue Termite-Proof Compounds Elmeridge have produced three compounds that are termite-proof. These cables were subjected to 54 days in a lab-based Australian termite mound, which are among the world’s most aggressive termites, with no adverse effects. Our commitment to producing quality cable is second to none. The compounds tested were Hytrel, Polyurethane, and Polyethylene. Glass Fibre Reinforced Plastic - Our pushrod cables for pipes and drains have proved to be the toughest on the market and can be pushed further than any others. This is

due to a special GFRP (Glass Fibre Reinforced Plastic) rod that is used in our cables, which is only supplied by Elmeridge. Our pushrod cables are available in various sizes.

Drain Pushrod Cable Steel Wire Armour - Elmeridge were contacted to supply the Spanish Navy with a 40-tonne breaking strain cable. Our design used a Kevlar aramid yarn and two contra-helically wound layers of Nitronic 50 steel wire armour. Due to confidentiality, we are not able to say how the cable was used, but it was successfully deployed and is fully operational.

Double Armoured Tow Cable Rodent-Resistant - We were approached by the Hong Kong transport department to provide our rodent-resistant rail cables for a major upgrade to their Metro system, prior to the transition from UK to Chinese rule on 1st July 1997. Following this, our

rodent-resistant cables have been installed extensively across the southern UK rail network, and the London Underground for trackside signalling and monitoring.

Rodent Resistant Rail Cable Single Core - We have supplied various cables over the years to Formula 1 management, using compounds such as Hytrel for single core cables in many different colours. Their in-car camera cables were breaking down and Elmeridge were approached to provide a solution to this problem. Our team was able to prevent vibration degradation of the braids within the cable, thereby solving the problem. Buoyant Fibreoptic Cable - Our buoyant fibreoptic cable is regularly in production, and most recently we produced a single 5km length of buoyant fibreoptic cable with a breaking load of 750kg, to view the condition of the culverts under London.

of fire hazard by grounding out the aircraft.

For almost four decades Elmeridge have built a reputation for designing, producing and distributing low voltage custom made cables.

Marine Fiber Optic Cable 36-Core Umbilical Cable - Another ingenious design from the team is our 36-core umbilical cable, designed for a ship’s radar navigation system. This can be fixed to a folding mast which is folded when passing under bridges and other overhead obstructions without damaging the cable, maintaining the ship’s systems and signals.

flexibility.

Medical Silicone Cable Sensor Cables - Elmeridge supply many different types of sensor cables, some of which are produced with an inner nylon vent-tube for pressure sensing. These cables have been supplied to companies in India, Europe, and the UK.

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Silicone Cable - Elmeridge were asked to supply two silicone cables with a reduced outer diameter to a medical company. Our team’s solution was to combine the two cables into one, thereby maintaining the required level of

Copper Braid - A project for the Royal Air Force was to supply a high-grade circular copper braid with a clear PVC sheath. This braid was attached to the aircraft during refuelling to prevent a build-up of static electricity, reducing the risk

CDT Cable - We are also proud to work with the British Antarctic Survey (BAS), supplying cables of 8,000 and 10,000 metres of CTD (Conductivity Temperature and Depth) Cables for the RRS Sir David Attenborough (pictured), and RRS James Clark Ross. For all production and distribution enquiries, our knowledgeable and helpful team can be contacted via our website - elmeridge.com. Our current lead times for production are approximately 8 to 14 weeks, depending on the cable specification and elements required. We regularly post news and updates that may interest you on our social media pages, so please remember to follow Elmeridge via the icons below.

For all production and distribution enquiries, our knowledgeable and helpful team can be contacted via our website:

For further information, please visit www.elmeridge.com | +44 (0) 1273 391810 Issue 78 PECM

ELECTRICAL & ELECTRONICS

INDUCTIVE ENCODERS PORTESCAP

A robust solution for precise motion feedback An inductive sensor, also known as an inductive encoder, provides fast and precise feedback of motor speed and position. Compared to optical and magnetic encoders, they can optimize the reliability of feedback for miniature motion applications. However, their specification for motion design requires careful consideration, especially for different operational and environmental conditions.

Sayali Shinde, Design Engineer at Portescap, discusses the technology behind inductive sensors. In a medical operating theatre, a hand-held surgical device, powered by a miniature BLDC motor, needs precise control to optimize the success of the procedure. Alternatively, a robot handling a tool for precision manufacturing needs accurate control to achieve micronlevel position adjustment.

In both these examples, an encoder is an essential feedback device that measures the speed or position of the shaft of an electric motor. The encoder communicates this information to the controller, which calculates the discrepancy between the setpoint and the actual speed or position. The controller then sends a corresponding signal back to the motor to correct any error. With this process operating continually at high speeds, this creates a closed loop

In a medical operating theatre, a hand-held surgical device, powered by a miniature BLDC motor, needs precise control to optimize the success of the procedure.

PECM Issue 78

system essential to precise speed or position control.

of an inductive encoder doesn’t diminish over time.

Encoders can operate on an optical principle, using a disk with patterns and optical sensors to detect position or rotation, yet dirt or dust can impact the reading. Alternatively, magnetic encoders, which rely on a magnetized disk and magneto

An inductive sensor operates on an electromagnetic principle, and signals speed and position changes by utilizing the interaction between its electromagnetic field and a motor shaft. An inductive coil is the main sensing element of an inductive sensor, and when an alternating current (AC) flows through it, the coil generates an electromagnetic field. A motor shaft within the proximity disturbs the field, which induces eddy currents, which are loops of current induced within a conductor when exposed to a changing magnetic field. These eddy currents create a secondary magnetic field, which interacts with the primary field of the sensor, and this interaction alters the inductance of the sensor’s coil, causing a change in its output signal. As the motor shaft rotates, the inductance changes periodically, and the frequency of these changes corresponds to its speed. Alternatively, the sensor can determine its precise angular position by tracking the exact phase of the inductance variations as the shaft rotates.

resistive sensors to detect magnetic field changes can be used. However, these devices are more affected by stray magnetic fields, leading to errors in environments with high electromagnetic interference (EMI).

Electromagnetic principle Other options include encoders based on electromagnetic induction, which are impervious to contamination but also less susceptible to magnetic fields. Unlike magnetic encoders, the performance

Advantages of inductive sensors Typically, adding an encoder adds length to the motor, and for flat or pancake-style BLDC motors, this extended length may negatively impact the motor-encoder assembly. However, inductive encoder technology also proves advantageous as the encoder elements and the commutation Hall sensor are situated on the same printed circuit board (PCB), maintaining the overall motor length compared to a standard encoder setup. Inductive sensors achieve fast response times. Changes in position or speed cause immediate alterations in the induced eddy currents, which directly affect the inductance of the sensor coil. This direct interaction between the field and the object enables real-time detection and feedback. These devices also enable high precision sensing, and inductive

encoders can achieve high resolution due to their ability to detect even small variations in the inductive signal. As the motor shaft rotates, its interaction with the sensor’s electromagnetic field causes measurable changes in the inductance of the coil, which are directly proportional to the position or speed of the object. Accurate measurement of these variations provides precise motion feedback. With inherently robust features, integration within the motor housing, and lack of mechanical components, this gives inductive encoders a long service life. Free of mechanical components such as optical disks, inductive encoders can also achieve a more compact design. These devices also typically have low power consumption, making them energy-efficient and suitable for battery-powered or portable power tool applications. Their relative simplicity also makes them easier to install and set-up, and for control system integration they can output various signal options such as PNP, NPN, or analog.

Support in specification An inductive sensor can still be affected by magnetic interference, and the presence of nearby metallic objects can interfere with the accuracy and reliability of inductive sensors, leading to false readings or inconsistent performance. Inductive sensor operation can also be compromised by EMI generated by nearby electrical devices or equipment. Some inductive encoders may also be unsuitable for sterilization environments, such as surgical applications, as they can suffer damage. While the integration of inductive sensors into miniature motion systems can be advantageous, their use requires appropriate specification according to operational and environmental considerations. Expert support in the selection of the right feedback sensor technology is useful to achieve long-term application success, as well as faster speed of development.

For more information, visit www.portescap.com Issue 78 PECM

ELECTRICAL & ELECTRONICS

EDGE COMPUTING AT ITS CORE SHUTTLE

Shuttle’s Industrial Edge PC Series The growing demand for intelligent, connected systems is driving computing power ever closer to where data is generated. In manufacturing, retail, transport and digital signage, edge computing enables data to be processed locally for lower latency, improved reliability and real-time responsiveness. Shuttle, a long-established manufacturer known for compact and reliable computer platforms, has developed the Shuttle Edge PC Series specifically for industrial and automation environments. These fanless systems combine robust aluminium enclosures with a footprint of just 120 × 75 × 51 mm and are designed for continuous 24/7 operation. With flexible VESA and DIN-rail mounting, they integrate easily into control cabinets, behind displays or within machinery. The Edge PC line-up currently includes four models sharing the same compact design but offering different capabilities. All are based on Intel Elkhart Lake or Atom x6000 processors and support up to 32 GB DDR4 memory. Dual 2.5-Gbit Ethernet, USB 3.2, a serial COM port and digital I/O provide the necessary interfaces for automation, control or monitoring tasks in demanding environments. The series covers a wide range of industrial scenarios. The SPCEL02 serves as a general-purpose solution for IoT gateways or data logging, while the SPCEL03 variant is specified for extreme temperatures between –20 °C and +60 °C, ensuring reliable operation even in harsh

These fanless systems combine robust aluminium enclosures with a footprint of just 120 × 75 × 51 mm and are designed for continuous 24/7 operation. industrial or outdoor conditions. The SPCEL12 model focuses on digital signage and multi-display applications, supporting up to three screens via two HDMI and one DisplayPort output. The latest addition, the SPCEL02P, introduces Power-over-Ethernet (PoE), allowing the system to be powered directly through the network cable – ideal where space or access to mains power is limited.

All Shuttle Edge PCs share a modular design with two M.2 slots for storage and expansion, enabling configuration with Wi-Fi 6, LTE or AI accelerator modules such as the Hailo-8. Compliance with MIL-STD-810G and EN 50121-3-2 standards underscores their industrial reliability, while a hardware TPM 2.0 module ensures secure boot and encryption. With their compact size, versatile connectivity and proven Shuttle quality, the Edge PC Series provides a practical foundation for modern automation, surveillance and smart infrastructure projects – delivering reliable computing power exactly where it is needed: at the edge.

Further technical details and documentation are available on Shuttle’s website: https://go.shuttle.eu/sB3yw

PECM Issue 78

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ELECTRICAL & ELECTRONICS

DETAILS DRIVE UPTIME FLIR

Thermal imaging in critical asset health monitoring Vision in manufacturing often revolves around the big picture: more production, greater efficiency, and steady growth. However, while big-picture goals define a company’s direction, true success lies in precision on the smallest scale. Details that are seemingly minute and often overlooked can make the difference between uninterrupted operation and costly downtime. There are hundreds and even thousands of components across a facility—from cable connectors to large-scale electric motors— keeping your workers safe, keeping your production lines moving, and keeping you competitive. Subtle vibrations, slight shifts in temperature, or an unusual data pattern can all signal much larger issues waiting to unfold. These “small” details, if left unchecked or unobserved, can be the catalysts for systemic failures with catastrophic consequences.

PECM Issue 78

Thermal Imaging: Bringing details to life With thermal imaging, companies can transform their reactive condition and process monitoring programs into proactive, predictive activities that ensure equipment repairs and replacements happen on a schedule instead of after a failure. Predictive maintenance is built on a foundation of routine, repeated critical asset monitoring that identifies equipment with high impact potential and builds a historical dataset of normal operating temperatures. This data is key to spotting changes in asset health and predicting the optimal time to take the equipment offline for repair. For example, the utility grid may wish to know what temperature a cable connection is under a particular electrical loading, to understand resistance and the likelihood of failure. Or, a production

plant may need detailed data on how hot an electric motor is when running at a known resistance in order to trust whether the motor will continue running flawlessly or fail. FLIR has long been a pioneer in the predictive maintenance space, specialising in the design and production of advanced thermal imaging cameras, components, and sensors. We continually invest in research and development and test real-world applications to ensure you’re able to capture the details that really matter.

Integrity of Image Good, useful thermal images need to be detailed, vibrant, and crisply focused. Our image processing technologies enhance thermal images— reducing noise and improving contrast— to provide you with clearest, sharpest visuals. Key to this technology is FLIR’s

proprietary Multi-Spectral Dynamic Imaging (MSX®) process, which overlays visible light details onto thermal images in real-time and provides users with a more complete understanding of the thermal scene. FLIR UltraMax® is another important image enhancement technology, in that it provides a final image with four times the data. UltraMax captures a rapid burst of thermal images in their original resolution and then compiles them within FLIR software into a single, higher definition image. This added detail, paired with up to four times more pixels covering the target area, does more than provide brilliant imagery; each pixel in a FLIR thermal image provides a temperature reading. By enhancing the image through UltraMax, users can also improve temperature measurement accuracy.

Data you can depend on: precision at pixel level Think of it this way: a thermal camera measures temperature with each pixel, so having more pixels on your target ensures a more accurate reading. This ability is crucial when small temperature variations can indicate potential issues. Say you’re inspecting a motor that typically has one section that runs hotter than the rest of the machine. If only one pixel is covering the hottest spot while the pixels around it cover cooler areas, you may not get the most accurate reading on the motor temperature. Having multiple pixels— and thus, multiple temperature readings—on that same critical hot spot will provide the most detailed heat analysis of subtle temperatures differences across an object or area. Your thermal images will therefore provide more than qualitative visuals: they’ll provide quantitative insights.

Change, Comparison, and Chronology Advanced thermography equips maintenance teams with a systematic approach to asset monitoring, enabling the identification of subtle issues that traditional methods

We continually invest in research and development and test real-world applications to ensure you’re able to capture the details that really matter. might miss. By focusing on the three Cs—Change, Comparison, and Chronology—businesses can unlock the big picture vision of asset health: minimising unexpected downtime, extending the lifespan of machinery, optimising overall operational efficiency, and keeping employees safe. • Change: Even minor temperature shifts can indicate early wear, stress, or failure, so it’s important to not only detect change at a moment in time but to also build a picture of how changes unfold over time. • Comparison: Inspectors should benchmark equipment across the same models with the same operating conditions and load. For

example, they can compare the performance of 120 motors across a single production line to rapidly identify outliers and potential failures. • Chronology: The ability to create a data timeline is critical to understanding temperature patterns over time and allow teams to predict future issues based on trends. Regular data capture (e.g., every three, six, or 12 months) builds this historical context, transforming snapshots into a meaningful diagnostic timeline.

Consistency, Control and Confidence Success in manufacturing depends on a big-picture vision built on detailed, real-time, information-rich insights. Thermal imaging-based condition monitoring is driving real strategic advantage at both the macro and the micro level, turning the 3C’s of Change, Comparison and Chronology into Consistency, Control and Confidence. This approach protects and enhances proactive production and overall asset health through system reliability, operational efficiency, and predictive maintenance planning and gives you the vision to see beyond the visible.

For further information, please visit www.flir.com Issue 78 PECM

ELECTRICAL & ELECTRONICS

POWERING PROGRESS FORTEC UK

FORTEC UK unveils a new era of high-performance power supplies FORTEC UK is proud to introduce the first phase of our refreshed power supply portfolio, an upgraded, modern range designed to deliver exceptional performance with a noticeably smaller footprint. Led by our Power Supply Division Manager, David Sproat, this launch marks a significant step forward in how we support engineers with reliable, efficient and intelligently engineered power solutions. With more than 20 years of industry expertise, David is guiding this rollout with a clear vision: provide compact, cost-effective products without compromising on quality or capability. Today’s engineers expect more from their power supply technology, long-term reliability, easier integration and confidence that the solution will stand up to the demands of modern systems. Our new range delivers exactly that. The first release includes Enclosed Power Supplies, DIN-Rail Power Supplies and dimmable LED Drivers. These products embody the principles at the heart of this refreshed portfolio: reduced size, competitive pricing, robust performance and dependable operation. By refining designs and adopting more efficient architectures, we’re able to offer the same power output as larger models while reducing installation space and cost. As part of a global technology group, FORTEC UK benefits from a strong international foundation while bringing specialist local expertise to the UK and Ireland. We combine world-class manufacturing partners with the knowledge of our in-house technical team, ensuring each

product portfolio and meeting the evolving needs of modern engineering applications.

This power supply launch reflects who we are: forward-thinking, engineering-lead and committed to making our customers’ lives easier. product is thoughtfully selected, rigorously evaluated and ready to support a wide range of industrial, medical, transportation, lighting and automation applications. New Strategic Partnership Furthermore, as part of our ongoing commitment to delivering exceptional value and performance, FORTEC UK is excited to announce our new partnership as an official Delta distributor. This collaboration allows us to expand our offering with Delta’s industry-leading range of Power Supplies, providing even more diverse and high-quality power systems to our customers. This strategic alliance demonstrates our dedication to enhancing our

Our team of technology specialists works closely with customers to solve complex challenges across displays, embedded computing, monitors, components and power systems. We help engineers make confident decisions, guiding them beyond initial specifications and uncovering solutions that improve efficiency, performance or sustainability. It’s an approach built on collaboration, curiosity and the belief that embracing complexity leads to better outcomes. This power supply launch reflects who we are: forward-thinking, engineeringlead and committed to making our customers’ lives easier. Each product is backed by the experience of experts who take pride in going the extra mile and supporting successful projects from concept to completion. Phase one is just the beginning. Over the coming months, further product releases will expand the range and continue strengthening our position as the first choice for innovative, expertly engineered solutions in industrial electronics. A new era of power starts here, and we’re excited to share it.

For further information, please visit www.fortec.uk

PECM Issue 78

HIGH PERFORMANCE POWER Cost efficient performance Compact smaller footprint design Quality you can rely on

Din-Rail Power Supplies Enclosed Power Supplies Dimmable LED Drivers Request a Quote

www.fortec.uk Issue 78 PECM

ELECTRICAL & ELECTRONICS

MEASUREMENT AND MITIGATION CP AUTOMATION

Making the right choices when addressing power quality issues Electrical networks are becoming increasingly complex, and so are the risks associated with poor power quality. From sags and swells to harmonics and transients, many issues develop long before their effects become apparent. Here, John Mitchell, global sales and marketing director at CP Automation, explains how a simple, structured approach to metering can help keep these issues at bay.

Analysers with high sampling rates, synchronised logging and the ability to correlate events across multiple locations enables users to trace disturbances to their point of origin. Without this depth of measurement, even experienced engineers are left relying on assumptions.

Report Quality data is only useful when clearly presented. Comprehensive reporting — with time-stamped logs, trend graphs and harmonics breakdowns — enables operators to understand both what happened and why.

As electrical networks become more populated with nonlinear loads, power quality issues are appearing more frequently – and often in places least expected. The only reliable way to manage these disturbances is to ensure the right metering is in place and that the output data is managed effectively.

Importantly, Class A measurement provides the confidence needed when liaising with the distribution network operator (DNO) or demonstrating compliance with standards such as G5/5.

Measure

Solve

The most important step in any power quality investigation is selecting the right meter. Engineering Recommendation G5/5 extended planning and compatibility levels up to the 100th harmonic (5 kHz), yet many meters still only measure to the 50th. This creates blind spots that can easily mask the root cause of failures. It’s important to select a Class A meter or an advanced analyser capable of capturing highfrequency harmonics, transients and long-term trends. Whether operators opt for portable spotcheck units or permanently installed monitors, visibility across the full spectrum is now essential.

It’s important to select a Class A meter or an advanced analyser capable of capturing highfrequency harmonics, transients and long-term trends. Analyse Once accurate data is captured, engineers can start to paint a picture. Power quality issues can unfold over microseconds or evolve slowly over weeks.

Effective mitigation is only possible with accurate measurements. Whether the solution involves harmonic filters, voltage optimisation, active compensation or adjustments to on-site equipment, the right fix depends entirely on the quality of the diagnosis. With clear measurements, precise analysis and robust reporting, solving power quality issues becomes targeted rather than reactive. For more information on power quality measurement and mitigation solutions and to speak to an experienced power quality expert, visit the CP Automation website.

www.cpaltd.net/industries/power-quality/

PECM Issue 78

CHOOSE THE RIGHT SOLUTION. GET THE FULL PICTURE. Power quality issues hide in the parts of the spectrum your meter can’t reach. Harmonics build quietly. Transients strike in millionths of a second. Equipment fails without warning. If your meter stops at the 50th harmonic, your visibility stops before the real problems begin. But today, even measuring up to G5/5’s 5 kHz limit isn’t always enough. As more modern electronic hardware enters plants and public networks, supra-harmonics in the 2–9 kHz and 9–150 kHz range are becoming a major source of disruption. Standards such as EN 61000-2-2 (public networks) and EN 61000-2-4 (industrial networks) recognise this issue — and many sites now require visibility all the way to 170 kHz to detect noise that interferes with communications, disrupts sensitive equipment and reduces overall equipment effectiveness and plant uptime. CP Automation can help you choose the right meter — fixed or portable — so you never operate blind.

MEASURE. ANALYSE. REPORT. SOLVE. Accurate measurement is only the beginning. With the right meter and the right support, you can move from detection to complete power quality protection. CP Automation offers a full portfolio of mitigation technologies, including: SineTamer® transient frequency attenuation devices

Active and passive harmonic filters from Comsys and REVCON

Engineered to suppress the damaging, ultra-fast events most meters barely catch.

Reducing distortion, stabilising voltage and protecting your equipment.

Power factor correction solutions From traditional capacitor banks and thyristor-switched systems to modern SVG and e-SVG technologies, with SVG/e-SVG providing advanced, anti-resonant compensation.

Resonance and voltage-regulation technologies Supporting sites affected by voltage dips and sags, ensuring stable operation.

Site-wide engineering support Ensuring the issue is not just identified but eliminated, and that you’re protected from future events.

With accurate data and proven mitigation technology, problems stop being recurring mysteries and start being permanently solved.

Contact CPA’s power quality team — we can speak to you about SineTamer and help you get to the root of the problem! Visit www.cpaltd.net

Email: sales@cpaltd.net Tel: +44 (0) 1724 851515

FACILITIES MANAGEMENT

DIAGNOSIS BEFORE PRESCRIPTION AXAIR FANS

Why technical support must start with understanding

By Andrew Jones, Technical Director, Axair Fans In medicine, no doctor worth their salt prescribes before they diagnose. Yet in our industry, the equivalent happens every day. A system underperforms, airflow isn’t right, energy use is high, or noise levels cause complaints, and the response is, “Let’s just swap the fan.” This is a prescription without a diagnosis. And just like in healthcare, it rarely leads to longterm improvement. It creates new problems, wastes money, and erodes trust. For too long, the fan industry has been shaped by giants who value sales and scaling revenue over care and detail. Customer enquiries are passed between departments, rushed into quotes, and pushed towards standard products listed on a sales plan, with minimal effort to understand the real application. The largest customers, those spending in the six-figure range, get the attention. Everyone else is treated as a distraction, left waiting weeks for answers to queries or technical issues, or worse, ignored. This complacency is normalised, and customers pay in inefficiency, downtime, and costly mistakes.

We believe the right prescription always starts with the right diagnosis. That means taking time to listen, be curious, and to interrogate what the system is doing and why it might be underperforming. It means challenging assumptions when someone believes the solution is simply a bigger fan, because in many cases, the real issue lies elsewhere. We ask the awkward questions, we look at the pressure, the ducting, the resistance, and the environment. We go deeper because a fan is rarely just a fan. It’s an integral part of a complex system that demands understanding, not guesswork. This way of working is more than a process, it’s a culture. Our core internal values were designed to be lived, not printed. Being attentive and focused, understanding before applying, showing resourcefulness in every customer interaction aren’t optional behaviours, they’re the way we do business. These values are the difference between being seen as just another supplier and being recognised as a trusted technical partner. That’s hard to do when people think you’re the small fish, but like restaurants or boutique hotels, you get better quality than large chains every time. We’ve worked with customers who are convinced they needed a larger fan to fix an underperforming system. Any number of suppliers would have happily take the orders, but we asked why. After a deeper conversation, it becomes clear the problem isn’t fan size at all but resistance in the ductwork. Replacing the fan would increase noise, add unnecessary energy use, and create further problems. By diagnosing first, we solve the root cause. The system performs

better, the costs stay controlled, and more importantly, the customer sees for themselves the value of our approach. That is what partnership looks like. We see this every day in service levels, diagnosing poor service levels and prescribing the Axair service level agreements is a proven solution that surprises a lot of our OEMs. Buyers today are overwhelmed. They’re navigating endless datasheets, online calculators, and selection software promising quick answers, but rarely telling the whole story. The temptation for large suppliers is to lean into that, to prescribe before diagnosing, because it protects their margins and keeps their volumes high. When technical buyers wait six weeks for a response, when “smaller” enquiries are brushed aside, the wrong solutions are pushed, trust is lost. We’ve built Axair to reject complacency. We’re proving there’s another way, one built on attentiveness, curiosity, technical depth, and personalised, accountable care for the customer outcome. Our role isn’t just to sell a fan, it’s to help you create better air systems. That belief has underpinned Axair for more than thirty years. It continues to be the reason our customers choose us over industry giants who see them only as a number on a sales report. It’s only now that we’ve dared to shout about it with conviction. So the next time your system isn’t performing, don’t settle for a quick-fix. Demand a proper diagnosis. When you do, the outcome isn’t just the right fan, it’s a better, more efficient, and more reliable system.

For further information, please visit www.axair-fans.co.uk

PECM Issue 78

National Business Development Manager

Michael Hambleton

Revolt. Reshape. Revolutionise. From bold claims to bigger results, meet the experts who made it happen. We disrupted the fan world with a message that raised eyebrows, and expectations. But revolting against the norm isn’t just a mood, it’s a mindset. Now, we’re putting the spotlight on the people who live that mindset daily. They don’t just deliver on promises, they are the promise. Fast, technical, collaborative, and a bit unexpected. You’re going to want to meet them. Let’s talk about you fan supply requirements to find out more. Axair. Revolutionary Fan Expertise.

www.axair-fans.co.uk

GEARS, DRIVES & MOTORS

MAINTAIN A COMPETITIVE EDGE KOBO

Well engineered industrial chain benefits Using a well-engineered industrial chain, is of paramount importance in industrial processes. These chains play a crucial role in various sectors of manufacturing. In this article, we look at the significance of wellengineered chains, their functions, benefits, and the consequences of neglecting them. 1. **Efficiency and Productivity**: Industrial chains are the backbone of production lines. Well-engineered chains, as supplied by Köbo UK Ltd, ensure the movement of materials, products, and equipment. They minimize downtime, enhance production efficiency, and boost productivity. 2. **Safety**: Safety is a paramount concern in any industrial setting. Well-designed industrial chains, like the ISO9001 Chains supplied by Köbo UK Ltd, are less likely to fail unexpectedly, reducing the risk of accidents and injuries. Properly engineered chains also mitigate the chances of chain-related accidents, such as chain derailing or snapping, which can have severe consequences. 3. **Durability**: Industrial chains are exposed to extreme conditions, including high temperatures, heavy loads, and corrosive environments. A well-engineered chain is constructed to withstand these conditions, ensuring a longer lifespan. This durability translates into cost savings as it reduces the frequency of chain replacement and maintenance. 4. **Cost Savings**: While investing in high-quality industrial chains may seem expensive initially, it pays

Neglecting the quality of industrial chains can lead to catastrophic consequences, including accidents, downtime, and financial losses. off in the long run. The reduced need for repairs and replacements, as well as increased operational efficiency, results in significant cost savings over time. In contrast, using inferior chains can lead to frequent breakdowns, expensive repairs, and higher operational costs. 5. **Precision and Accuracy**: Industrial processes often require precision and accuracy. Wellengineered chains provide the required consistency in movement and positioning, ensuring that products meet the desired specifications. 6. **Customization**: Industrial chains can be tailored to specific requirements. Well-engineered chains can be designed to accommodate various load capacities, speeds, and operating conditions. 7. **Environmental Impact**: Sustainable manufacturing practices are becoming increasingly important. Well-engineered chains can be designed to minimize energy consumption and reduce emissions. They contribute to greener operations by running

more efficiently which aligns with environmental regulations and corporate social responsibility goals. 8. **Reduced Downtime**: Downtime can be a significant cost factor in industrial processes. Well-engineered chains are less prone to unexpected failures, reducing the frequency and duration of downtime. This, in turn, improves overall production continuity and customer satisfaction. 9. **Global Supply Chain Reliability**: In today’s interconnected world, supply chains often span across countries and continents. Well-engineered industrial chains ensure the reliability of these global supply chains. 10. **Quality Control**: Quality control is a critical aspect of industrial processes, particularly in sectors like automotive and aerospace. A well-engineered chain contributes to consistent quality by maintaining precise movement and positioning, crucial for the assembly of intricate components. In conclusion, the importance of using industrial chains, in processes cannot be overstated. These chains serve as the lifeline of various industries, contributing to efficiency, safety, cost savings, and environmental responsibility. Neglecting the quality of industrial chains can lead to catastrophic consequences, including accidents, downtime, and financial losses. Therefore, investing in wellengineered industrial chains is not just a matter of choice but a strategic imperative for any organization aiming for long-term success.

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

PECM Issue 78

GEARS, DRIVES & MOTORS

REDUCED PROJECT TIMES NORD

NORD enables virtual commissioning of its drive solutions NORD now offers digital twins for system development. Based on a myNORD configuration, it is now possible to request individually created drive systems as simulation models. This allows engineers to verify early in the planning phase whether the drive concept is suitable for the system. Virtual commissioning significantly reduces the project time – even for complex systems. Since the publication of the FMI (functional mock-up interface) technical standard in 2010, it has become more and more common to work with simulation models in system planning. NORD DRIVESYSTEMS also uses data-based simulations for the development of its components and drive solutions. The system provider is now using this knowhow to help its customers achieve greater efficiency and availability of its drive systems even in the planning phase by offering a digital service: With digital twins of its drives, NORD enables virtual commissioning.

Simple online configuration Users can configure drive systems or components for their requirements as usual via the myNORD customer portal. They select components and their features such as performance, mounting options or outputs. Then, they can request a simulation model for the fully configured drive system. The process was developed by NORD in cooperation with the software company Machineering from Munich, which specialises in virtual commissioning.

The advantage of these digital twins of the NORD solutions is the significantly faster availability of the entire system. Just a few weeks until actual commissioning The advantage of these digital twins of the NORD solutions is the significantly faster availability of the entire system. The simulation models are inserted into a similarly simulated system. In this environment, the drive configurations can be extensively tested. If adjustments are required, they can be easily implemented based on the data. Errors can be remedied in the early stages of development, avoiding potential later damage. Only once the virtual drive system has been

validated by the customer, it will be manufactured and delivered by NORD. As the drives are already functionally integrated into the system control at this point, actual commissioning is possible in a very short time. The overall process from configuration to commissioning is reduced from several months to only a few weeks.

High-efficiency IE5+ motors already available virtually Virtual commissioning of drive systems is of special interest for any technically demanding solution. Therefore, NORD particularly focuses on components that play a decisive role in automating production processes. The manufacturer is kicking off the virtual commissioning with its range of high-efficiency IE5+ and IE4 motors, along with the corresponding gear units and frequency inverters. Simulation models will then gradually become available for other NORD product areas as well.

For further information, please visit www.nord.com

PECM Issue 78

GEARS, DRIVES & MOTORS

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) www.crossmorse.com +44 (0)121 121360 3600155 0155 | |sales@crossmorse.com 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 78 PECM

Engineering Process

Control &

Expos MANUFACTURING PECM is proud to partner with the following industry shows Engineering Supply Chain at MACH 2026

Welcome to the CHEMUK 2026 Group of Events, the UK’s largest B2B trade show supporting the chemicals, process engineering, and formulated product industries. The expo will present 600+ specialist exhibitors and 100+ expert speaker sessions, split between five focused show zones: • Chemicals Supply Show Zone • Chemicals Management Show Zone • Process & Chemical Engineering Show Zone • Chemical Laboratory Show Zone • Formulated Product Manufacture

Subcon is growing - and it’s growing fast • 6000+ Visitors • 200+ Exhibitors • 100+ CPD-accredited courses • More to see & do than ever! In just two years, we’ve seen an 85% surge in visitors and a 30% increase in exhibitors. The momentum is real and you don’t want to miss the opportunity to get in front of a rapidly expanding audience of engaged manufacturing buyers. Exhibit at Subcon, 3–4 June at the NEC Birmingham - the UK’s go-to event for sourcing, supply chain solutions, and manufacturing innovation.

The Festival of Advanced Manufacturing & Engineering 03 - 04 June 2026 | NEC Birmingham Where change-makers can find insights, solutions & connections for their manufacturing & engineering projects. Organised by The Manufacturer - market experts trusted by our established audience to create, curate and deliver content of value.

Why Southern Manufacturing & Electronics? Discover 550+ exhibitors from a range of industries including Aerospace, Mechanical Engineering, Motor Sport, Electrical Engineering, and more! Network and connect with like-minded professionals from the likes of McLaren, Dyson, Rolls-Royce, Siemens and more.

PECM Issue 78

The Engineering Supply Chain zone is the perfect place if you’re looking to find capacity and capability within the UK based supply chain. Whether it’s cuttingedge manufacturing technologies and solutions or looking to reshore your current supply chain you’ll be able to speak to exhibitor who can help. The five-day event will feature a range of companies from the UK supply chain who can help with solutions and help with your business requirements. Register now for your FREE fast-track visitor pack.

Connect with thousands of decision-makers actively looking for new suppliers. With 200+ subcontractors, cutting-edge tech, CPD-certified workshops, live demos, and industry-leading keynotes, Subcon is where business gets done. Showcase your capabilities. Meet serious buyers. Grow your pipeline. Subcon delivers.

Advanced Engineering is the only UK event connecting all industrial ecosystems, driving high-value manufacturing and supply chain solutions. Here, the brightest minds in design, engineering, and manufacturing come together to solve real-world challenges, accelerate innovation, develop skills, and build a more sustainable future. From net-zero composites to energy-efficient processes, visit the future of engineering.

BIG names, Exciting innovations, Great opportunities. It’s all coming your way at the UK’s leading free-to-attend processing and packaging machinery event – The PPMA Show® 2026 held at Birmingham’s NEC from 22-24 September 2026.

Web: www.rotechsystems.co.uk Email: sales@rotechsystems.co.uk TEL: +44 (0)151 356 2322

MONITORING THE WORLD!

Rotech Motion Sensor’s can be used whenever information or monitoring of a shaft rotation, position, direction, speed, slip etc. is required!

Rotech Motion Sensor’s can be used wherever materials are transported or processed by conveyors, elevators, screws, mixers etc! Rotech Systems has an excellent worldwide reputation when it comes to rotation monitoring. We have been in business for over 40 years, servicing many diﬀerent industries from the food Industry to the mining sector. Our products are extremely robust. Guaranteeing the end user a trouble free solution, to all their monitoring applications.

Rotech Motion Sensor’s can be used for indication, control, interlocking, protection, sequencing, alarm initiations and many more functions!

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 78

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

HEALTH & SAFETY

A 2026 PERSPECTIVE Health and Safety in Engineering and Manufacturing Health and safety in engineering and manufacturing have always been critical priorities, but by 2026 they have evolved into far more strategic, technology-driven, and peoplecentred disciplines. As industries continue to embrace automation, digitalisation, and sustainability, the approach to protecting workers has shifted from reactive compliance to proactive risk prevention and continuous improvement. In 2026, health and safety are no longer viewed as standalone functions but as integral components of operational excellence and organisational resilience.

The Changing Risk Landscape Engineering and manufacturing environments remain inherently hazardous, involving heavy machinery, high temperatures, chemicals, electrical systems, and complex processes. However, the nature of risk has changed. While traditional hazards such as manual handling injuries, machinery accidents, and exposure to harmful substances persist, new risks have emerged alongside technological advancements. The increased use of robotics, autonomous systems, and artificial intelligence has reduced some physical risks but introduced others, including human–machine interaction failures, system malfunctions, and cybersecurity-related safety incidents. Additionally, the growing pace of production and demand for flexibility can increase cognitive load, fatigue, and stress among workers. In 2026, organisations recognise that health and safety must address both physical and psychological wellbeing to remain effective.

Technology as a Safety Enabler One of the most significant developments in health and safety by

PECM Issue 78

2026 is the widespread adoption of digital tools. Smart sensors, wearable devices, and the Industrial Internet of Things (IIoT) now play a key role in hazard identification and real-time monitoring. Wearables can track worker fatigue, posture, and exposure to noise or hazardous substances, alerting individuals and supervisors before incidents occur.

Predictive analytics and artificial intelligence are increasingly used to analyse historical incident data, near misses, and equipment performance. These systems can forecast potential failures or highrisk scenarios, enabling preventative maintenance and targeted safety interventions. Digital twins of factories and engineering systems

allow organisations to simulate processes, identify hazards during the design phase, and test safety controls before implementation, significantly reducing risk at the source.

Human-Centred Safety Culture Despite technological progress, the human element remains central to health and safety in 2026. Leading organisations understand that technology alone cannot prevent accidents without a strong safety culture. This culture is characterised by leadership commitment, open communication, and active employee involvement. Workers are encouraged to report hazards and near misses without fear of blame, fostering a learning environment rather than a punitive one. Safety leadership training has expanded beyond supervisors to include engineers, designers, and senior executives, ensuring safety considerations are embedded in decision-making at every level. In engineering and manufacturing, design for safety has become standard practice, with engineers accountable for eliminating hazards before systems reach the shop floor.

The push towards greener manufacturing, including new materials and processes, requires thorough evaluation of potential health impacts. roles can involve high pressure, shift work, and job insecurity driven by automation and market changes. Employers now recognise that stress, burnout, and poor mental wellbeing can lead to increased accidents, reduced productivity, and higher staff turnover. Organisations are implementing structured wellbeing programmes, offering mental health training for managers, access to support services, and flexible working arrangements where possible. Risk assessments increasingly include psychosocial factors alongside physical hazards, reflecting a more holistic approach to worker safety.

Mental Health and Wellbeing

Regulation and Compliance in 2026

By 2026, mental health is firmly established as a core component of occupational health and safety. Engineering and manufacturing

Health and safety regulations continue to evolve to keep pace with technological and societal change. By 2026, regulators place

greater emphasis on risk-based approaches rather than prescriptive rules. Organisations are expected to demonstrate effective safety management systems, continuous risk assessment, and competence across their workforce. Environmental sustainability is also closely linked to health and safety compliance. The push towards greener manufacturing, including new materials and processes, requires thorough evaluation of potential health impacts. Engineers and safety professionals must collaborate closely to ensure that innovations aimed at reducing environmental impact do not introduce unforeseen risks to workers.

Skills, Training, and the Future Workforce The engineering and manufacturing workforce of 2026 requires new skills to manage modern safety challenges. Digital literacy, systems thinking, and an understanding of human factors are increasingly important. Training has moved beyond classroom-based instruction to immersive methods such as virtual and augmented reality, allowing workers to practice responding to hazardous scenarios in a safe, controlled environment. Continuous professional development is essential, as technologies, regulations, and best practices continue to evolve. Organisations that invest in safety competence not only reduce accidents but also enhance productivity, quality, and employee engagement.

Conclusion In 2026, health and safety in engineering and manufacturing are defined by integration, innovation, and inclusivity. Advances in technology have transformed how risks are identified and managed, while a stronger focus on culture and wellbeing ensures that people remain at the heart of safety efforts. As industries continue to change, organisations that treat health and safety as a strategic priority rather than a compliance obligation will be best positioned to protect their workforce, maintain operational excellence, and build a sustainable future. Issue 78 PECM

HEALTH & SAFETY

TRAPPED KEY INTERLOCKING SENTRIC SAFETY GROUP

Strengthening safety protocols in the renewable energy sector As global demand for renewable power accelerates, wind energy has become one of the fastest-growing contributors to clean electricity generation. Both onshore and offshore wind farms continue to scale in size and complexity, presenting operators with new safety challenges. With turbine heights now exceeding 150 metres and internal machinery becoming increasingly compact and powerful, maintaining safe access for technicians is more critical than ever. The diverse hazards within a turbine; electrical energy, rotating equipment, hydraulic systems and confined spaces, require safety solutions that are robust, reliable and immune to human error. Traditional administrative controls or electronic safeguards alone are not enough. In harsh, remote environments, wind operators need physical certainty that hazardous energy is isolated before any maintenance begins. This is where trapped key interlocking has become essential.

Mechanical certainty for high-risk Environments Trapped key interlocking provides a simple, proven and inherently safe method of controlling hazardous energy. By enforcing a precise sequence of operations, these systems ensure that power cannot be restored while a technician still has access to a dangerous area. Conversely, access points such as switchgear panels, nacelle doors, rotor locking mechanisms or tower ladders cannot be opened until the relevant energy sources have been fully isolated. Trapped key interlocking is not only used inside the nacelle doors, but also in the

• Confidence for personnel, who can rely on the physical assurance that the turbine is safe Combined with broader emergency response plans and adequate operator training, trapped key interlocking forms a vital part of a multi-layered safety strategy. substations that interconnect the turbines to the grid infrastructure.

Sentric Safety Group: Engineering safety you can depend on

Trapped key interlocks perform reliably in extreme conditions, from the humidity of offshore marine environments to the temperature swings of remote onshore sites. The mechanical nature of the system eliminates the possibility of override or bypass and provides a level of failure resistance unmatched by digital-only solutions.

At the Sentric Safety Group, we recognise that the success of renewable energy is inseparable from the safety of the people who operate it. Our Castell trapped key interlocking systems and engineered safety solutions are designed specifically to meet the growing demands of modern wind power generation, both onshore and offshore.

Integrating interlocking into modern safety protocols As wind farms expand into multiturbine, multi-gigawatt assets, their safety frameworks must evolve accordingly. Today’s operators need a combination of engineered controls and procedural discipline. Trapped key interlocking supports this by establishing safe access pathways and embedding non-negotiable sequencing into turbine operation. Integrated correctly, interlocking systems enhance: • Zero-energy verification before technicians enter hazardous zones • Consistency in maintenance procedures, reducing reliance on human judgement • Compliance with international safety standards, including IEC and ISO requirements

We work closely with turbine manufacturers, wind farm operators and maintenance providers to deliver high quality systems that enhance safety, reduce downtime and support full compliance, and we also offer custom design solutions when the requirement is less typical. Our solutions ultimately provide certainty in environments where mistakes are costly and conditions are challenging. Wind energy is a key pillar of global decarbonisation. With the right safety technologies in place, led by reliable, mechanical interlocking, operators can ensure that the future of renewable power is not only efficient and sustainable, but ultimately safe too.

For further information, please visit www.sentricsafetygroup.com/us

PECM Issue 78

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

A GREENER WAY TO GRIT ECOGRIT

Rethinking winter safety for a greener future In a market long dominated by rock salt, EcoGrit has positioned itself as a forward-thinking challenger with a simple message: winter safety doesn’t have to come at the expense of the environment. Based in the UK, the company has developed EcoGrit Concentrate, a non-toxic, biodegradable de-icer designed to work effectively in harsh conditions while avoiding the damage associated with traditional salt. Rock salt, though cheap and familiar, brings a series of welldocumented problems. It corrodes vehicles and metalwork, degrades concrete and paving, harms soil quality, and increases salinity in waterways. For pets and wildlife, it can be even more hazardous, causing chemical burns to paws or toxic reactions if ingested. EcoGrit aims to solve these issues by offering a formulation that is both gentle on surfaces and safe around animals, children, and plants.

the hidden costs of salt-based grit. EcoGrit’s challenge—and opportunity—is to lead that conversation, demonstrating that eco-friendly alternatives are not only viable but often superior.

One of EcoGrit’s strongest selling points is performance. The company claims its product remains effective down to –20°C, far below the temperature range where rock salt becomes unreliable. This efficiency allows for less frequent application, which not only reduces labour but also cuts down on material use and long-term cost. For households, schools, care homes, and businesses responsible for public access, this offers a practical and sustainable alternative during cold snaps.

the UK faces more sudden freezes and cold spells each year. Safer pathways and roads are essential, but so is the responsibility to protect ecosystems already stressed by pollution and climate change. By reducing reliance on corrosive salts and chemical de-icers, EcoGrit argues that communities can support both public safety and environmental stewardship.

EcoGrit also frames its mission within a broader environmental context. With climate patterns growing increasingly unpredictable,

Of course, shifting public behaviour away from rock salt requires education and awareness. Many people simply don’t realise

In a world demanding smarter, cleaner solutions, EcoGrit presents a compelling case: winter protection can be effective, responsible, and sustainable. If widely adopted, this small change in how we tackle ice could have a meaningful impact on infrastructure, ecosystems, and the wellbeing of people and pets alike.

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

PECM Issue 78

MACHINING & MACHINERY

INDUS Engineering Services Precision in every panel Unlock efficiency with custom control panels tailored to your needs At INDUS Engineering Services, we specialize in creating bespoke control panels designed for reliability, performance, and ease of use. Whether you’re in manufacturing, automation, or any other industry, our expertly crafted panels are built to streamline operations and optimize performance.

Why Choose INDUS? Tailored Solutions: Our control panels are designed and built to meet the specific needs of your business, ensuring seamless integration into your systems. Industry Expertise: With over 10 years of experience, we understand the unique demands of industries such as manufacturing, automation & FMCG.

Our Services Include: • Custom Control Panel Design & Fabrication • PLC & HMI Integration • Automation & Process Control Solutions • Panel Upgrades & Retrofits • Electrical Engineering Consultations • 24/7 Maintenance & Support Services

High-Quality Components: We only use the best materials and components to ensure long-lasting and efficient performance, helping you reduce downtime and maintenance costs. Compliance & Safety: All our products are designed to meet the highest safety standards and comply with relevant industry regulations. Rapid Turnaround & Support: From design to delivery, we ensure quick, reliable service and offer ongoing support to ensure your systems run smoothly.

T: 01202 942637 | E: info@indusengineering.co.uk | W: www.indusengineering.co.uk Issue 78 PECM

MACHINING & MACHINERY

SMART COBOT CONVEYORS ADAPTTECH

mk Belt Conveyors Controllable by UR Cobots mk’s GUF-P 2000 series of belt conveyors are true all-rounders, with a large selection of drives, tails, stands and belt types for outstanding variability. They are based on the mk 2000 aluminium profile range, which provides high load-bearing capacity and a torsion-resistant structure. In addition to its low height of 50 mm and a compact ø 53 mm driving roll – which can be coated with rubber according to the application – the conveyor also offers a wide range of different belt types. As with all mk belt conveyor systems, the crowned design of the driving and idler rollers ensures significantly easier belt adjustment. The system is available with an optional stationary or rolling knife edge. System slots running along both sides (10 mm slot width in accordance with mk’s profile technology) allow you to easily integrate the conveyors into existing machine frames or to attach stands, side rails, sensors and other accessories. In addition to our wide selection of side rails and stands, we also offer a standard range of end stops and electrical accessories. A further quality feature of this conveyor system is the stainless steel sheet installed below where the belt runs, which ensures longterm wear resistance of the belt. The mk Technology Group is now also part of the Universal Robots partner network and provides GUF-P 2000 belt conveyor technology which can be integrated quickly and simply into your cobot application through the URCap plugin to control operation mode and speed of the conveyor.

mk provides all users of Universal Robots with individual GUF-P 2000 belt conveyors for simple integration in their cobot application. The convenient URCap plug-in simplifies the set-up and programming of the conveyor. The UR+-approved belt conveyor GUF-P 2000 has a suitable version for every application. Conveyors are available in widths from 50 to 800 mm and lengths up to 10,000 mm. In addition, maximum total loads of 75 kg and speeds of up to 80 m/min are possible. As belt conveyors generally transport the goods without any special requirements in terms of their position or support geometry, they are particularly suitable for vision-supported processes. Since the belt conveyor is constructed in a modular aluminium profile construction, it has T-slots in the conveyor frame on both sides. These facilitate integration into the system as well as enabling side rails, sensors

Email info@adapt-tech.co.uk

PECM Issue 78

Call (01949) 823751

and other accessories to be attached. The mk-Conveyors-URCap plugand-play solution ensures fast and problem free communication between the conveyors and the cobots. It is compatible with all UR models in the e-series. Installation is simple and the intuitive user interface allows you to control up to 2 belt conveyors. The conveyor receives the commands for start/ stop, direction and speed via the plug-in, but can also convey goods up to a sensor signal or for a certain period of time. The process layout remains customisable, even without programming knowledge. As the sole UK & Ireland distributor for mk conveyors, AdaptTech Manufacturing Solutions can help you optimise your UR cobot processes and use mk belt conveyors together with the free URCap plug-in which can be found at www.adapttech.co.uk. Get in touch to find out more!

Visit www.adapt-tech.co.uk

mk Conveyor URCap Simple & quick automation with cobot and belt conveyor

mk is part of the UR+ network of Universal Robots Fast and easy communication between the mk belt conveyor and UR cobot mk URCap offers an intuitive interface for controlling up to 2 belt conveyors No programming knowledge required

www.adapt-tech.co.uk

MACHINING & MACHINERY

UNIQ DIRECTCOOL MAPAL

Decentralised cooling for maximum effect With the DirectCool option for the UNIQ hydraulic chuck range, MAPAL launched a future-forward solution that takes cooling and the process reliability of machining to a new level. The technology addresses the requirements of modern machining processes and is cost-effective, technically refined and easy to integrate. The UNIQ range of hydraulic chucks was introduced by MAPAL in 2020 and continually expanded ever since. The UNIQ DReaM Chucks for boring and reaming applications and UNIQ Mill Chucks for milling operations are established on the market with a large customer base. A key feature was recently added to the UNIQ portfolio in the form of the DirectCool option. DirectCool is a decentralised cooling system that enables precise cooling along the tool shaft to the cutting edge through three cooling channel bores. This allows the hydraulic chucks to achieve even temperature distribution, reduce wear and thermal distortion, significantly increase tool life, and enable consistent machining quality. At the same time, the flushing effect improves process reliability and surface quality, as chips are removed effectively. DirectCool supplies reliable cooling and prevents tool breakage, particularly in boring processes where chips can wind around the tool. The UNIQ hydraulic chucks have unlimited compatibility. DirectCool integration does not alter tool restriction, so existing processes can be continued without adjustments.

UNIQ DirectCool is already producing promising results, particularly in stainless steel and aluminium machining. Cost-efficiency and flexibility are also assured, as no expensive shank grooves are required and standard tools and/or tools without internal cooling can be used.

is optionally available for UNIQ Mill Chucks, HA and UNIQ DReaM Chucks with 4.5° outer geometry in diameters from 6 to 32 mm.

Background: What sets the UNIQ hydraulic chucks apart UNIQ hydraulic chucks have an identical outer geometry to the shrink chuck. At the same time, the hydraulic chuck can be distinguished externally from shrink chucks due to its glossy surface and blue screw in the HSK collar. UNIQ hydraulic chucks are highly durable and corrosion-resistant. MAPAL has picked up several design awards for the chuck.

UNIQ DirectCool is already producing promising results, particularly in stainless steel and aluminium machining. The technology was officially presented at EMO 2025 in Hanover and represents a clear commitment to hydraulic clamping technology from MAPAL. For the market launch, DirectCool

For further information, please visit www.mapal.com

PECM Issue 78

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

MACHINING & MACHINERY

Cleaner, greener, and more efficient: Oil-free solutions for aluminium machining MANUFACTURER OF HIGH QUALITY

ANTI VIBRATION PRODUCTS

A leading US automotive supplier revolutionised its aluminium machining and cleaning process with HAKUFLUID® 185 and HAKUPUR 439-1, achieving cleaner parts, extended bath life, and improved sustainability.

New premises supports continued growth of control panel manufacture

WIDE RANGE OF STOCK AVAILABLE FOR NEXT DAY DELIVERY

01282 878200

sales@fibet.co.uk | www.fibet.co.uk Fibet Rubber Bonding (UK) Ltd Unit 9 Dale Mill, Hallam Road, Nelson, Lancashire, BB9 8AN

Switching to HAKUFLUID® 185, a mineral oil-free, watersoluble coolant, eliminated INDUS Engineering oil contamination inServices the HAKUPUR is proud to439-1 offerneutral a wide range cleaner bath, preventing of custom control panels, re-contamination of and automation systems aluminium die-cast housings. special purpose machinery. This ensured consistent After working on major control cleanliness and longer and automation projects bath life—extended from for several of the south’s one to three weeks—while leading brands, the company maintaining has recentlyproductivity. acquired a new

premises with the aim of Trials confirmed foam-capacity increasing production free, stable cleaning baths, of bespoke and sub-contract, reducing maintenance and control panel manufacture. non-conforming parts. The The new premises will also plant optimised allowfurther us to support the efficiency by of lowering bath wider range engineering

activities carried out by the company, such as the design, temperatures from 60°C to manufacture, and testing of 40°C, cutting energy costs special purpose machinery. and enhancing biostability. Also, to further our goals to reduce our carbon foot print By embracing oil-free we will be installing a high technology, the supplier efficiency solar PV array in not only met strict For more the coming months. cleanliness standards but information on the services also significantly reduced that are available please do environmental not hesitate toimpact— contact and setting a be new benchmark we will happy to discuss for sustainable aluminium your project needs and machining and cleaning. requirements. www.kluthe.com www.indusengineering.co.uk

Issue 72 PECM

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Issue 78 PECM

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 74 86

66 PECM Issue 78 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!

MACHINING & MACHINERY

BRIGHAM BOOSTS CAPACITY HT BRIGHAM & CO LTD

Rhodes Press refurbishment elevates capacity

Michael Benham, Ops Director (left), Doug Allen, CEO (centre) and Allan Murray, MD (right) welcomes the 250 tonne press investment

Leading metal presswork specialist HT Brigham & Co Ltd has announced a significant enhancement to its manufacturing capabilities with the strategic refurbishment of a 250ton Rhodes progression press. This investment marks a decisive step in strengthening the company’s metal forming operations and increasing capacity across its production lines. The move is set to bolster uptime resilience and directly supports growing customer demand by ensuring greater reliability, flexibility, and throughput in high-volume pressing applications.

PECM Issue 78

Speaking about this development, Doug Allen, Chief Executive of HT Brigham, whose extensive background in aerospace manufacturing underscores a commitment to both strategy and operational excellence, articulated the company’s vision. “At the core of our Brigham Operating System (BOS) is the understanding that for our people to thrive – and they are the bedrock of our success – we must provide them with the optimal environment and the best tools,” Allen states, echoing the foundational principle of BOS that a positive environment nurtures

thriving individuals, leading to optimised processes and fulfilled organisational purpose. The investment follows a management buyout in 2022 and represents a broader strategic vision driven by data-led decisionmaking and continuous performance analysis. The revitalisation of the Rhodes press—an industrial workhorse in high-volume, multistage forming operations—further enables Brigham to execute complex metal forming processes with increased consistency, reduced downtime, and enhanced flexibility.

Ultimately, the Rhodes press refurbishment serves as a clear signal of HT Brigham’s long-term commitment to advancing the standards of metal presswork. This decision not only extends the operational life of a critical asset but also future-proofs the company’s production capabilities against shifting market dynamics and increasingly stringent quality demands. With over 75 years of experience in delivering metal pressings across a spectrum of volumes and applications, HT Brigham’s reputation for precision and dependability is deeply rooted in its evolution from a single-hand-press workshop to a modern facility equipped for global supply. The refurbishment of the Rhodes press is a testament to that heritage, marrying long-established manufacturing know-how with

Anna Lavender-Moore, Compliance Director with the 250 tonne Rhodes press

a commitment to innovation. It reflects a blend of legacy and agility—an approach that allows the company to scale with confidence while maintaining tight tolerances and repeatability in demanding production environments. This investment also reinforces HT Brigham’s ability to provide uninterrupted, high-volume output—a critical requirement in sectors where supply chain

continuity and production reliability are non-negotiable. Ultimately, the Rhodes press refurbishment serves as a clear signal of HT Brigham’s long-term commitment to advancing the standards of metal presswork. Through strategic investment, technical refinement, and operational foresight, the company remains firmly positioned at the forefront of UK manufacturing.

To learn more, visit https://brighampressings.com/ Issue 78 PECM

MACHINING & MACHINERY

ABB UNVEILS NEW MTG ABB

ABB launches new box gauge for aluminum hot rolling mills ABB has launched a new version of its Millmate Thickness Gauge (MTG) technology that brings precise aluminum thickness measurement to the final stages of the hot rolling process. The new MTG Box Gauge extends the proven performance of the MTG technology into hot rolling environments. MTG Box Gauge measures aluminum strip thickness below 8 millimeters at the tail end of hot rolling, where accurate data is crucial for ensuring product quality and production efficiency. Protection against the demanding conditions encountered in hot rolling processes is ensured by a refined IP66 sealing that shields the interior sensor components from contact with emulsions used to manage friction and control temperatures during rolling. The new design also features an optimized internal air flow that channels cool air toward heat sensitive electronic boards, while expelling warm air through the base of the unit. This can reduce the operating temperature of the transmitting coil by as much as 40°C, contributing to greater durability and improved efficiency. Using ABB’s pulsed eddy current technology, MTG Box Gauge avoids the complexity and safety issues associated with X-ray systems. The MTG Box Gauge also enables precise single-side measurement without the need to mount sensors on both sides of the strip. This not only simplifies installation and maintenance but also reduces space requirements in the mill,

the final stage of hot rolling has traditionally been a complex task for aluminum manufacturers,” said Lars Karlsson, Global Product Line

making it particularly valuable where access to the underside of the strip is limited. Unlike traditional thickness gauges that require recalibration for different aluminum alloys, the MTG Box Gauge delivers consistent, accurate results regardless of alloy type. This alloy independence helps manufacturers simplify setup, reduce downtime, and maintain continuous rolling across mixed production schedules. “Maintaining precise and reliable thickness measurements during

Manager at ABB’s Measurement & Analytics division. “Our MTG Box Gauge is the ultimate solution for aluminum hot rolling mills. Building on its proven success in cold rolling mills, this innovative factory cali-brated gauge offers improved durability to handle the toughest conditions. With alloy independence, safe technology, minimal maintenance, and singleside measurements, the MTG Box Gauge ensures pre-cision, reliability, and efficiency in aluminum hot rolling processes.” In October 2025, ABB received the “Manufacturer of the Year” award at the Instrumentation & Electronics Awards for helping the aluminum industry optimize production, reduce waste, and achieve its decarbonization goals.

For further information, please visit www.abb.com

PECM Issue 78

MACHINING & MACHINERY

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.

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.

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

Dawn of a new era at Markyate Precision Machining Markyate Precision Machining is entering a new era as Managing Director Dean Bygate leads the next stage of the company’s evolution. With long-term contracts secured across defence, energy and industrial markets, Dean is reshaping the business for the demands of modern UK manufacturing while staying true to its family-run foundations. A key milestone this year was the acquisition of a dedicated new unit for assembly and packaging operations. This expansion not only strengthens the company’s commitment to contract manufacturing but also allows the main facility to be reorganised for improved flow, productivity and increased capacity. To support this growth, Markyate has invested in advanced automation — including a new Matsuura H.Plus-405 multipallet machining centre. This high-utilisation platform increases spindle uptime, supports existing production requirements and opens valuable capacity for new opportunities. People remain central to the company’s strategy. As Dean explains, “Our biggest investment isn’t machinery — it’s the

exciting young talent we’re bringing through the business. Their capability and ambition are what will drive Markyate forward over the next decade.” This focus is reinforced by structured development pathways and hands-on training across the shopfloor.

Markyate Precision Machining is positioning itself for the next decade of high-accuracy, high-reliability manufacturing in the UK.

With expanded capability, a modernised layout and a new generation of leadership,

www.markyateprecision.co.uk

Issue 78 PECM

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

[ Designed for your profit ]

The new benchmark in universal turning UNIVERSALTURN 50

HIGHLIGHTS

More performance. More precision. More future. All-purpose turning machine for precise and high-performance machining With the new UNIVERSALTURN 50, EMCO sets the next milestone in complete machining of bars and chuck parts. Developed for maximum precision, dynamics and process reliability, the compact high-performance turning centre offers everything that modern manufacturing centres require: powerful drive systems, an integrated Y-axis for extended milling and flexible automation concepts. Whether complex turned and milled parts for mechanical engineering, the automotive industry, medical technology or defence – the UNIVERSALTURN 50 impresses with its outstanding rigidity, intuitive operation and scalable equipment.

• High-precision turning centre for efficient complete machining of bars up to 51 mm bore • Integrated Y-axis for extended milling and maximum machining versatility • Highly dynamic drive systems for fast machining cycles and maximum accuracy • Compact counter spindle for precise rear-side machining without additional re-clamping • Powerful tool turret with up to 12 driven tool positions • Scalable automation solutions – from integrated swivel loaders to gantry systems • Stable cast machine bed for maximum rigidity, damping and process reliability • Absolute measuring system for maximum repeat accuracy without reference point homing • Intuitive operation with SINUMERIK ONE – optionally available with FANUC 0i plus control from 2026 • Perfectly coordinated machine concept for applications in mechanical engineering, automotive, medical technology, defence and more • Made in Austria

FOR THE BEST MACHINING QUALITY, PRECISION & COMPACT MACHINE CONSTRUCTION

SMALL FOOTPRINT EMCOTURN E25 CNC turning center for bar stock work up to Ø 25 mm (1”) and also chucking work. The EMCOTURN E25. Uncompromising quality right down to the last detail at a very reasonable price. With an extremely solid machine base, a thermo symmetric spindle headstock, high precision spindle bearings, preloaded roller guideways in all axes, a fast 12 stn tool turret and your choice of Sinumerik 828D or Fanuc 0i TD. Available with driven tools, C axis for main spindle, Manual tailstock with automatic quill.

See the machines at MACH 2026 Hall 17 – Stand 130

ONE OF THE UKs UKs LARGEST STOCKISTS OF QUALITY NEW & FULLY REFURBISHED CMMs CMMs

Jo in an us a de tt lec he tro UK nic ’s l s s ead ho in w, g m St an an uf d n ac o. tur P1 in 70 g

Quality Control Technology are a one stop solution for all your business CMM requirements, we have the largest stock of New and Refurbished CMM’s in the UK, with over 30 years’ experience of CMM service, calibration and repair. New CMMs

The ‘Quantum 4 CMM Range’ is built and designed at QCT’s UK works and is available in a variety of standard frame sizes, other sizes can be built on request. All CMM’s are supplied with our bespoke software and interfaces. The Quantum 4 offers outstanding build quality and cost to performance ratio.

New Ace Portable Inspection Arms

The ACE arm offers portable measuring capability for the largest of projects as well as the flexibility to take the measuring machine to the object. Like our Quantum range, the Ace measuring arm offers exceptional quality and is the perfect system for contact and noncontact 3D measurements with the addition of the laser scanning options.

Refurbished CMMs

At QCT we only select high quality used machines, completely strip and overhaul them. Each used machine is rigorously tested, with all pneumatic pipes replaced, air bearings removed, cleaned, serviced & refitted. Electronics are tested & unsupported items are replaced with new. The original interface and controller are replaced with QCT’s own along with a new computer and operating system. QCT refurbished machines are supplied as a full turnkey package, fully backed with a comprehensive warranty. Re-using the frame of a pre-used CMM means that fewer resources are required to produce them, reducing their carbon footprint.

Subcontract CMM Inspection

CMM Calibration to UKAS ISO 10360

CMM Service & Repair

CMM Relocation

CMM Retrofits

T: 01332 572 882 E: sales@qctderby.co.uk www.cmmsales.co.uk

QUALITY CONTROL TECHNOLOGY LIMITED Westside Park l Belmore Way l Derby l DE21 7AZ

lis tab he

QCT also offers an ongoing calibration and service contract package to ensure your CMM is operating at its optimum.

Service and Calibration of all CMMs

QUALITY CONTROL TECHNOLOGY LTD

1992

MEASUREMENT & MONITORING

FLOW TECH CUTS COSTS BURKERT

ICB Distillers set to reduce production costs with contact-free flow meter

The FLOWave flowmeters deliver up to 50% water saving and minimise the time for cleaning cycles.

Drinks producer ICB Distillers wanted to reduce production costs while maintaining hygiene and product quality. Introducing Bürkert’s FLOWave flowmeter to provide accurate measurement without media contact, ICB Distillers has been able to minimise product wastage as well as decrease the volume of water required to flush its CIP process. At ICB Distillers’ Middlesbrough site, the company produces spirit-based drinks, developing beverages for its own range as well as blending and mixing drinks for various brands and supermarkets. The plant also hosts a bottling facility, producing around 30 million retailready bottles each year. Spirits such as rum as well as ethanol are transported to the facility where they are mixed with an array of ingredients, such as fruit juices and

PECM Issue 78

creams, plus purified water and sugar, according to the recipe.

Managing product quality When the tanker arrives at ICB Distillers Middlesbrough, the spirit or ethanol flows into a bund containing six tanks. Then, when drinks production takes place, the alcoholic liquid is fed into mixing tanks according to the recipe requirements and alcohol by volume (ABV) level of the particular beverage. This pipe matrix is flexible and allows ICB Distillers to achieve various mixes and create new products as required. Accurate flow measurement of the spirits and ethanol is crucial to ensure the quality of the beverages, as well as precisely manage stock and optimise the cost efficiency of production. It’s also vital that flow measurement devices integrated

into the matrix maintain hygiene, and with various spirits flowing through the pipes at any one time, preventing cross-contamination is also essential. ICB Distillers also relies on a clean-inplace (CIP) process, and while it must rinse away all chemicals, minimising water consumption is key to lowering costs and managing sustainability. Up to now, residual spirits within the pipe matrix have also been washed away in the CIP process, with product wastage adding significant cost.

Reducing production costs “Spirits left in the line have been washed away during CIP” explains Gary Bragman, Project Manager at ICB Distillers. “It was important for us to move to a system that could integrate a pigging system, save on water, and control product flow with greater accuracy.”

which also achieves a significant environmental benefit.” With Bürkert’s FLOWave flowmeters installed on each of the feedlines from the bund, ICB Distillers’ phased commissioning set the first meter live in May, and its flow control accuracy is already improving production efficiency.

Improving production efficiency “Previously, challenges in accuracy controlling the flow of spirits using mag-based flow meters meant continually adjusting the mixture, adding highly purified water to help meet the ABV level, as well as sugar and other ingredients,” explains Gary. “Now, with Bürkert’s FLOWave, we can get a much more accurate measurement of what’s going into a mixing tank before pumping it to the line. From initial batches of 500 litres, each one has been accurate to less than two litres difference.”

The information displays are in the control room while the flowmeters are in an ATEX Zone 2 hazardous area.

A pigging system is named after the ‘pig’, a bung that is pushed through the pipes to recover product and assist in cleaning the lines ahead of CIP. To achieve this, a pipeline integrating flow meters that wouldn’t obstruct the ‘pig’ was required. Engaging with Bürkert, engineers Kieran Bennett and Chris Hughes from the flow specialist specified the FLOWave flowmeter. Free of seals, electrodes, and components within the flow path, the device minimises the potential of bacteria accumulation and is easy to clean. To achieve accurate flow measurement, FLOWave sends high-frequency Surface Acoustic Waves (SAW) across the fluid where changes in flow, mass, temperature, and density, affect the waves’ speed and attenuation. The resulting detection of the signal achieves precise measurements without direct contact with the media.

Reduced water use in CIP Bürkert’s FLOWave was also specified to improve the cost effectiveness and time required for CIP. A typical cleaning process operates by setting cycle times of chemical washes followed by clean water flushes. To ensure completeness of the flush, conservative estimates are applied, but this results in a high volume of water use.

The FLOWave design enabled the move to a new cleaning system.

Minimising spirit wastage and reducing the volume of water used in the CIP process is set to achieve a rapid return on investment for the beverage producer. However, FLOWave can detect the phase change in the media, referred to as the differentiation factor. This accurately informs when all chemical traces from the CIP process have been flushed away, enabling a shorter flushing period and reduced water use. With at least one CIP process per day, and tens of thousands of litres of water involved per year, the cost and time saving is significant,” says Kieran Bennett, Bürkert. “Total water saving can be up to 50%,

The flow meters are installed within an ATEX Zone 2 hazardous area, while the devices communicate back to a Bürkert ME61 display located in a separate control room. The FLOWave device integrates analogue and digital outputs, and by wiring the digital communication ports together in a daisy chain formation, a single cable, approximately 25 metres long, connects to the display via Bürkert’s EDIP CAN-based protocol. Providing individual batch and total flow rates, the data enables ICB Distillers’ operations team to accurately keep track of produce. With the additional flow meters set to be commissioned in the following months, ICB Distillers will be in a position to extend the pigging system across the matrix. Minimising spirit wastage and reducing the volume of water used in the CIP process is set to achieve a rapid return on investment for the beverage producer. Meanwhile, less time required for the updated cleaning process has the potential to improve productivity while maintaining the same high level of hygiene.

For further information, please visit www.burkert.com Issue 78 PECM

DIVERTER VALVES

IT’S IN THE VALUE WE ADD DMN-WESTINGHOUSE is an independent producer with 50 years of exclusive commitment to rotary and diverter valves. Supported by 25+ R&D experts and a dedicated diverter production and testing site, we produce plug, tube, flap, and ball diverters in a range of versions, always aligning your valve to your needs. Our global network with 75+ local partners is at your service. Learn more at dmnwestinghouse.com

PTD plug diverter valve

SPTD plug diverter valve

SPTDS plug diverter valve

GPD plug diverter valve

BTD ball diverter valve

FDV flap diverter valves

2-TDV tube diverter valve

3-TDV tube diverter valve

M-TDV tube diverter valve

PROCESS TECHNOLOGIES

ENGINEERING EXCELLENCE DALBY

Driving innovation in high-specification aerospace finishing Founded in 1972, Harry Dalby Engineering has become a leading supplier of commercial Paint finishing equipment. Today the company continues its passion for innovation. With years of experience in industries ranging from Automotive and Rail to Aerospace and Industrial manufacturing, Dalby offer bespoke solution based products of the highest quality, exceeding the needs of the most demanding installations. We are a specialist engineering business that has rapidly become a leader in advanced aerospace paint finishing environments. Operating at the intersection of aerospace, defence, and highspecification manufacturing, Harry Dalby Engineering has built a reputation for delivering some of the most technically advanced spraybooth / oven facilities currently operating within the UK’s aviation sector. Aerospace finishing environments demand precision, environmental control, compliance, and long-term operational efficiency. Recognising this, Harry Dalby Engineering has specialised in the design and installation of purpose-built aerospace spraybooths capable of meeting the most stringent industry requirements. The company has successfully delivered: • Custom-built spraybooths within existing aircraft hangars • Brand-new standalone spraybooth installations • Military and civil aircraft finishing facilities • Specialist solutions for landing gear

PECM Issue 78

systems and sub-assemblies Each project is engineered to maximise workflow efficiency while ensuring consistent coating quality, environmental performance, and compliance with aviation standards. The UK remains a global centre of excellence for aerospace and advanced manufacturing, and Harry Dalby Engineering plays a key role in supporting this position through innovation-led project delivery. The company’s strength lies in its ability to integrate: • Advanced airflow management systems • Precision temperature and humidity control • Energy-efficient extraction technology

• Smart design for safe operator access and workflow optimisation These features collectively deliver spray environments that not only meet today’s production demands but are also scalable for future aircraft programmes. In both military and civil sectors, reliability and repeatability are non-negotiable. Harry Dalby Engineering’s facilities are designed to ensure long-term operational resilience while supporting critical maintenance, repair, and overhaul (MRO) operations. From fast-jet repainting programmes to commercial fleet livery changes and landing gear refurbishment, the company’s spraybooth solutions enable

customers to uphold the highest quality standards while reducing downtime and operational risk. As UK engineering faces increasing pressure to improve sustainability, productivity, and digital integration, companies like Harry Dalby Engineering are proving that infrastructure investment is crucial to maintaining global competitiveness. By creating efficient, compliant, and future-ready finishing environments, the company is actively contributing to: • Improved production turnarounds

In both military and civil sectors, reliability and repeatability are nonnegotiable. expertise continues to elevate British manufacturing capabilities. With an expanding portfolio and a growing reputation across defence and civil aviation, our company is not simply building spraybooths it

is building the infrastructure that enables the aerospace industry to perform at its best. Harry Dalby Engineering is setting a new benchmark for aerospace finishing environments in the UK.

• Higher quality assurance outcomes • Lower long-term operational costs • Reduced environmental impact through modern design Their work demonstrates how engineering excellence at the facility level directly supports excellence in aircraft manufacturing and maintenance. Harry Dalby Engineering stands as a clear example of how specialist For further information, please visit www.dalby.co.uk Issue 78 PECM

PUMPS

THE DUAL PUMPS STORY DUAL PUMPS

Celebrating 50 years of excellence Founded by Tony Herridge in 1975, Dual Pumps Limited has grown from a small garage-based operation into a leading distributor of pressure washers, pumps, and fluid-handling components. Over the past five decades, the company has built a reputation for reliability, innovation, and quality service. Tony worked as a sales representative for Hypro in the UK and Europe, a role that would prove instrumental in shaping the company’s future. This early experience laid the foundation for lasting business relationships. His work soon led to partnerships with other major brands, including Interpump, Pratissoli, Banjo, Pacer, and Flojet, marking the beginning of a long and successful collaboration that would help define Dual Pumps’ product offering. In 1977, the company opened its first office in Oakham with two employees before expanding to Melton Mowbray in 1982. A major milestone came in 1983 when Dual Pumps became the official UK distributor for Interpump, the world’s leading manufacturer of high-pressure plunger pumps.

As Dual Pumps marks its 50th anniversary, it stands as a testament to growth, resilience, and dedication to customer satisfaction.

Innovation has always been central to Dual Pumps. In 1996, it launched its first product catalogue, later expanding to a 160-page edition in 2001. Today, the company offers a 432-page catalogue and a mobileresponsive B2B website featuring over 10,000 products, streamlining the purchasing experience for trade customers.

35,000 sq. ft. facility on the outskirts of Melton Mowbray in 2012, enabling it to meet increasing demand and enhance service offerings. The launch of the Evolution Series Engine-Driven Pressure Washers in 2015, featuring over 60 models across ten series, further cemented the company’s reputation for highperformance, durable products tailored to industry needs.

Recognising the need for greater capacity, Dual Pumps moved into a

In 2020, Dual Pumps achieved ISO 9001-2015 certification,

demonstrating its commitment to quality and continuous improvement. Looking Ahead to 2025 and Beyond As Dual Pumps marks its 50th anniversary, it stands as a testament to growth, resilience, and dedication to customer satisfaction. The company now employs 44 people, serving over 2,500 customers, from sole traders to international OEMs, and distributing products from more than 90 leading global manufacturers. From humble beginnings to becoming a trusted partner worldwide, Dual Pumps continues to set the standard for reliability and innovation. With a strong foundation and a vision for the future, it remains committed to delivering high-quality solutions for an ever-evolving industry. At Dual Pumps, dependability isn’t just a promise—it’s a legacy.

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

PECM Issue 78

1975

2025

Dependable Under Pressure Established in 1975, Dual Pumps Ltd is a leading supplier of pumps, fluid handling components, agricultural & industrial spraying products, pressure washers, pressure wash accessories & cleaning equipment.

celebrating

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100

UK Official Distributor

All our Engine Driven Machines are hand built in the UK

Since 1983

www.dualpumps.co.uk Tel: 01664 567226 • Email: info@dualpumps.co.uk Follow / Like / Subscribe

PUMPS

SULZER WINS FPSO ORDER SULZER

Seatrium selects Sulzer’s leading pumps packages for Petrobras P-84 and P-85 FPSOs Global pump OEM Sulzer has won an order to supply multiple water injection packages to Seatrium for Petrobras’ next generation P-84 and P-85 Floating Production Storage and Offloading (FPSO) vessels. The project was awarded to Sulzer due to its track record of providing industry-leading pumps for the most challenging offshore oil and gas operations globally. For both vessels, Sulzer has met the strict acceptance criteria and application requirements of the end user. To support the construction of both vessels, Sulzer will deliver fully integrated pump skids designed to provide maximum efficiency in a compact footprint. Each package incorporates three BB5 9.5 MW water injection pumps with two BB1 660 kW booster pumps, as well as two BB2 850 kW seawater booster pumps – all evolutions from Sulzer’s proven hydraulic portfolio. The skids will arrive complete with tested pumps, motors, couplings and controls. Bruno Antoniassi, Senior Manager of Sales and Application Engineering at Sulzer Brazil, said: “Sulzer is proud to again collaborate with Petrobras and Seatrium, following our successes in the P-78, P-80 and P-83 projects. This latest order demonstrates our worldwide supply chain cooperation and engineering capacity. The global integration of our technical expertise in Switzerland and Germany, with our engineering capacity here in Brazil, means we can streamline

This latest order demonstrates our worldwide supply chain cooperation and engineering capacity. the delivery of these packages to shipyards in Brazil, China and Singapore for multiple schedules. “Prior to deployment, we will manufacture the pumps and integrate them here in Brazil, then carry out testing at full power. Following that, we will assist in installation, commissioning, and site integration tests. Once in the field, our team is ready to provide local aftermarket engineering support for the next 30 years in operation.”

Brazil’s national oil company, Petrobras will deploy the new FPSOs in the Atapu and Sépia fields around 200 km of the coast of Rio de Janeiro. When completed by Seatrium, a leading global provider of engineering solutions to the offshore, marine and energy industries, the vessels will set new standards for efficiency and throughput. Each vessel will offer an oil production capacity of 225’000 barrels per day (bpd) and process 10 million m3 of gas every day, while featuring efficient technologies that are estimated to reduce greenhouse gas emissions intensity significantly. Bruno concludes: “Our global reach, local capabilities, strategic technical relationships and deep application understanding will ensure a stateof-the-art pump solution that meets the latest standards of both the EPC and end user.” Delivery is scheduled for early 2026, with advanced stages of testing already underway at Sulzer facilities.

For further information, please visit www.sulzer.com

PECM Issue 78

STORAGE, HANDLING & DISTRIBUTION

GAS HANDLING AT LNG TERMINALS BURCKHARDT COMPRESSION

Compressor technology and reliability Across the LNG landscape, compressors play a crucial role in the efficient transport and storage of gas. Their continued reliability and efficiency are essential for effective operations in modern gas supply networks. Ageing assets can benefit from upgrades and overhauls that use the latest materials and reverse engineering techniques to update compressors and extend their service life. Even if different manufacturers supplied the original equipment, it is possible to find expertise and knowledge from a single source that can support a variety of machines and keep downtime to a minimum. Rakesh Kulkarni, Engineering Sales Manager at Burckhardt Compression, looks at landbased compressors and how their performance can be improved. Downstream applications in LNG terminals predominantly use oilfree reciprocating compressors. These avoid the need for lubrication systems and filter maintenance as making oil separation and gas filtration technologies unnecessary, guaranteeing the cleanliness of the heat exchangers and high-pressure re-liquefaction system.

Managing boil-off gas Oil-free compressors are integral to the efficient and safe operation of LNG terminals. Their primary function is to manage boil-off gas (BOG)—the vaporized LNG that results from ambient heat absorption during storage and transportation. By compressing BOG, these compressors enable its re-liquefaction or use as fuel, minimizing product loss and reducing emissions.

PECM Issue 78

Accurate data collection is crucial for identifying maintenance issues

Oil-free reciprocating compressors are favored for this role due to their ability to handle cryogenic temperatures, with inlet gas temperatures reaching as low as -170°C. They are designed with specific materials for wear components, such as piston rings and seals, to ensure reliability and minimize maintenance under these extreme conditions. Common designs such as the Laby® and the Laby® GI have been developed by Burckhardt Compression. These compressors are specifically designed for both landbased and marine LNG applications. They can compress gas to 300 bar without cylinder lubrication, making them suitable for both reliquefaction processes and on-board vessels with dual-fuel engines.

continuous supply of natural gas to meet consumer demand, enhancing the flexibility and reliability of the energy supply chain. Compressors are also used for transport over longer distances and at local storage and delivery stations to maintain gas pressure. This entire infrastructure should be properly maintained to ensure safe and reliable operation, leading to decades of dependable service. However, ageing assets will eventually need more significant interventions if they are to continue working without being replaced. Experienced service providers can provide comprehensive revamps, including reverse engineering parts and introducing upgraded materials.

Comprehensive assessments Managing the local energy grid Once BOG is reliquefied or used as fuel, the processed natural gas can be introduced into the distribution grid. This integration ensures a

The event that determines the need for an intervention can range from a change in local legislation, such as emissions regulations, to an unplanned outage that affects

provider with an OEM background could deliver alternative options. The ability to reverse engineer parts supported by all the required documentation is crucial to providing a fast response. Options can include upgrading the original material specifications as well as improving clearances and sealing solutions.

productivity immediately. Whatever the reason, the process to identify the best solution remains the same. The first step in revitalizing a compressor is completing a comprehensive assessment to understand the condition of the equipment, the urgency of any repairs and potential benefits of this work. Obtaining sufficient information requires a structured assessment that uses advanced measurement techniques and data analysis to identify any issues. Using data available from the operator’s process, as well as any additional sensors that may be required for a comprehensive picture, in-depth analysis should identify any bad actors. The major issues can be categorized into three main groups: reliability, excessive energy consumption and gas emissions. Each group has a direct effect on the business and should be addressed methodically to deliver data-driven insights and effective solutions.

Precision measurements The monitoring and protection of reciprocating compressors is now covered by the 5th edition of API 670, released in November 2014. Plants operating these machines will often categorize them as critical equipment and therefore put in place sensors to collect important data. Over time, continuous operation causes clearances to go out of tolerance, which will induce vibrations. Sensors can be installed in several locations as part of the machine build or portable equipment can be used to establish vibration levels periodically. Whichever option is chosen, this data is some of the most important information needed to determine any potential issues. Velocity sensors can also be used to determine vibration in the frame, crosshead, and cylinder. Their positioning is crucial in achieving accurate data that can be used to pinpoint issues. Working with the OEM or a maintenance provider

A typical terminal equipped with LNG compressors

With many machines having completed decades of service, materials technologies have progressed significantly since their original design was conceived. In the intervening years, there have been many significant improvements in materials and machining technologies which can now be used to extend the service life of existing assets.

Extending piston life by 300%

Experienced service providers can provide comprehensive revamps, including reverse engineering parts and introducing upgraded materials. experienced in this application should ensure that all sensors are correctly located and calibrated. Problems with valves, such as sticking or lost springs, can be isolated if crank angle data is available. This should be complemented with accelerometers and velocity sensors, which can be used to measure vibration, gas leak malfunctions and overloading.

Analyzing the options Having established the areas of the compressor that require attention, the next step is defining the best course of action. There may be short- and long-term solutions and the operator needs to be aware of all the options. The OEM may not be able to deliver immediate support and replacement parts for older machines may have a long lead-time. This is where an independent service

The BOG compressors at an LNG terminal were suffering from reduced reliability – the 1st stage pistons needed to be replaced every four years. The operator had approached the OEM for a solution, but they did not respond with any support. This led to Burckhardt Compression being approached to investigate and resolve the problem. The LNG storage tanks used perlite for insulation and in the older tanks it had come away from the tank walls and was being carried through the pipework to the compressors. In the cylinders, it acted like a grinding paste, predominantly damaging the 1st stage piston, but some perlite carried through to the 2nd stage as well. Increased clearances and wear to the piston ring grooves caused the sealing rings to become dislodged and trapped in the valve port, causing the rings to break. The material for the rider rings had been selected poorly and all stages were missing pressure release grooves. As a result, the original rings would be changed after 8,000 hours.

New materials The engineering study determined that the best option for an improved design would be an aluminum, Issue 78 PECM

single-piece 1st stage piston, installed with new rider rings using a material optimized for dry-running, high speed and high load applications. These would be matched with a specialist coating applied to the piston rod and a new cylinder liner, designed by Burckhardt Compression. These improvements were projected to increase the mean time between overhaul (MTBO) from 8,000 hours to more than 24,000 hours.

Eliminating the need to flare

Trusting in decades of expertise

The review found that the process had a desuperheater that was operating in bypass mode, so the first cooling step was not being used fully. This caused an extended cooling time, during which the gas had to be flared. By adopting a different procedure where the compressor runs in bypass mode and using the desuperheater, there would be no need to flare the gas.

At a time when LNG operations are under increasing scrutiny from an environmental standpoint a process review, even on a relatively new installation, can deliver improvements and cost reductions. For older installations, a review of legacy parts can reveal opportunities for improvements in terms of both materials and design.

Due to the perlite being carried over to the 2nd stage, and on occasions to the 3rd stage, all the sealing rings were upgraded to the proprietary material from Burckhardt Compression. Since the upgrade was completed, the 1st stage rings have a minimum service life of 24,000 hours, while those in the 2nd and 3rd stages have been checked and reinstated, achieving over 72,000 hours of reliable service.

In addition, Burckhardt Compression recommended modifying the start-up sequence when both compressors were needed to meet demand. As part of the comprehensive review, further suggestions were made to improve the packing to reduce leakages. Further recommendations on components that would improve reliability and ease of maintenance, such as valve covers with pressure bolts and improved bearing design for increased load bearing capacity were submitted. This revised operating process could make a significant reduction, around 25 tonnes CO2e per year, in the carbon footprint of the terminal and will also cut the financial

Process modifications In another example, an LNG terminal had a process that needed the compressors to start and stop frequently. While they were coming up to speed, the operation needed to flare the gas. This had both a financial cost as well as environmental implications and required regular dialogue with the local authorities. Predominantly, the duty compressor would run at 50% capacity while the stand-by unit remained offline. Each month, the compressors would switch operations to rotate the duty cycle and share the running interval. Each time the duty compressor came online, the operator was flaring the gas for up to an hour before the gas temperature was stable and low enough to prevent high-temperature trips. The issue was process related, rather than a specific problem with the compressors’ design. The terminal’s engineering team called in Burckhardt Compression to investigate and recommend a solution that would improve the situation. After a detailed discussion about the existing process and the reasons for flaring the gas, it was possible to make some recommendations.

losses of burning the gas. In addition, these changes would minimize the risk of environmental fines, at a time when local legislation was being tightened.

Burckhardt Compression has developed its BC ACTIVATE assessment program, which analyzes and evaluates a reciprocating compressor from any manufacturer and delivers a series of recommendations for improvements. Extensive data collection and analysis, coupled with decades of experience, result in a range of solutions that will improve performance, reliability and service life. While operators of reciprocating compressors can call on this expertise as required, the most effective solution is to engage in a long-term service agreement (LTSA) which adds value to the business, with improved lifecycle costs, operational efficiency and accurate preventive maintenance. Together, this partnership ensures the compressors continue to deliver dependable service, with planned outages and revamps scheduled for optimum performance.

Expert on-site support is essential for fast turnarounds

For further information please visit www.burckhardtcompression.com

PECM Issue 78

STORAGE, HANDLING & DISTRIBUTION

Battery and Energy Storage Europe to spotlight Battery Passport implementation beyond EVs Battery and Energy Storage Europe has announced a dedicated programme focused on EU Battery Passport implementation, addressing compliance challenges beyond electric vehicles and into stationary, industrial, grid-scale, long-duration, and emerging battery applications. While Battery Passport requirements are well understood in the EV sector, the Barcelona-based event will focus on often-overlooked areas including stationary energy storage, industrial batteries, grid-scale systems, and applications in aerospace, maritime, and rail electrification. With the event taking place in September 2026, just five months ahead of the February 2027 legal deadline, the programme will bring together industry leaders, technology providers, and policy experts to address sector-specific implementation challenges. The Battery Passport programme will explore practical topics such as digital infrastructure, data management, supply chain integration, verification processes, and recycling traceability, supported by case studies, technology demonstrations, and collaborative discussions designed to accelerate industry readiness.

The Battery Passport is a digital record tracking a battery’s full lifecycle, from raw materials and manufacturing to performance, carbon footprint, and recycling. From February 2027, it becomes mandatory for rechargeable EV, industrial, and LMT batteries over 2 kWh sold in the EU.

Ken Davies, Conference Programme Director, said the regulation represents a major industry shift, noting the event’s focus on turning compliance into competitive advantage across the full battery ecosystem. Battery and Energy Storage Europe takes place 8–9 September 2026 at Fira de Barcelona, Gran Via.

Issue 78 PECM

TOOLS, PLANT & EQUIPMENT

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 78

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 78 PECM

TOOLS, PLANT & EQUIPMENT

Linear Motion Specialists

Authorised NSK & Nippon Bearing Distributor

RM Fowler Ltd High precision linear guides and ball screws NSK K1 lubricating units to extend maintenance intervals NH series available with high temperature design 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

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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 78

TOOLS, PLANT & EQUIPMENT

LHS 210 P AND LHS 410 WELWYN TOOL GROUP

High-Performance Compressed Air Heaters from Leister The new LHS 210 P and LHS 410 P are Leister’s first compressed air heaters designed for operating pressures up to 6 bar, providing machine builders with a powerful solution for integrating highperformance components into increasingly compact systems. Both models combine efficiency, pressure resistance, and space-saving design to meet the growing demands of modern industrial processes. Each model features a reinforced housing engineered to withstand high-pressure conditions. Because they operate with external compressed air, no additional blower is required—making the LHS 210 P and LHS 410 P ideal for systems with limited installation space. Additionally, the power connection housing is positioned outside the airflow, ensuring quick, safe, and convenient installation. The screw-thread and modular design of the LHS 210 P and LHS 410 P allow the use of a wide range of adapters for maximum flexibility. At the air inlet, both compressed air or blower adapters can be used, while at the air outlet, options include double flange, tube-filling, nozzle, or thermocouple adapters. This modularity enables the LHS 210 P and LHS 410 P to be easily adapted to various industrial processes, including packaging, food processing, automotive manufacturing, and tube production. The LHS 210 P delivers 2000 W or 3000 W at 230 V, making it perfect for applications with tight installation spaces. For more demanding heating tasks, the LHS 410 P provides 3600 W or 4400 W

Each model features a reinforced housing engineered to withstand high-pressure conditions. at 230 V, and up to 5500 W at 400 V, offering higher performance while maintaining a compact footprint. Both models are designed to meet diverse power requirements without compromising space efficiency. For added safety, the air inlet flange of both models includes a relief valve that automatically vents excess pressure, ensuring a safer operating environment. Each heater can be

configured as a single or double flange unit, providing maximum flexibility for integration into your system.

LHS 210 P and LHS 410 P – Compact, versatile and safe Developed by Leister, the LHS 210 P and LHS 410 P are supplied to the UK by Welwyn Tool Group. Welwyn supply the full range of Leister plastic welding and industrial process heat equipment and offers highly competent technical support by their team of dedicated engineers. For further information and technical advice for equipment in this field, please contact Welwyn Tool Group on 0800 856 0057, email them on info@welwyntoolgroup. com, or visit their website www.welwyntoolgroup.com

For further information, please visit www.welwyntoolgroup.com Issue 78 PECM

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

4. Reverberatory Furnaces Reverberatory furnaces are characterised by their elongated rectangular shaped hearth and

TOOLS, PLANT & EQUIPMENT

their metal casting operations. T +44 (0)1702 472201 www.monometer.co.uk

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

Modernised copper processing in Rwanda and Zambia: How Monometer is supporting emerging industrial Markets A new area of growth in copper trade for certain countries across Africa is rising, supported by Monometer’s supply of new melting technology. This is technology offering reliable, high-quality metal processing for the conversion of scrap materials to specification ingot suitable for export. This export of ingot from such countries as Zambia and Rwanda is new and emerging, supported by newly established local manufacturing capacity utilising exclusively Monometer furnaces and ancillary equipment. These installations support regional valueadded production. However, performing effectively in emerging industrial areas requires more than equipment alone; it requires technical understanding, robust systems, and effective operator training for a working partnership to succeed. Monometer has been working closely within these markets, our recent project in Rwanda comprising the installation and commissioning of a complete melting and casting system — including a Monometer rotary furnace, casting machine, and filtration unit — now fully operational and producing copper ingots to specification.

Both Rwanda and Zambia are seeing a gradual shift toward more controlled, professionalised metal-processing operations, and our ongoing work in these regions places Monometer in a position of early leadership. The technical complexity of establishing such facilities — from material handling to furnace performance to achieving consistent casting quality — requires specialist knowledge that cannot be improvised or quickly replicated.

This achievement reflects more than a successful installation. It demonstrates Monometer’s ability to deliver reliable, well-engineered solutions in regions where infrastructure, a workforce of often limited experience and feedstock variations, present unique demands. These are not projects that succeed through equipment alone; they succeed through practical expertise, training, planning, and hands-on support — areas in which Monometer has built a strong reputation over decades.

As production continues in Rwanda, the results reinforce what we have long believed: that well-designed rotary furnace systems, implemented with care and supported by experience, enable meaningful industrial progress. Monometer is committed to supporting this advancement, building long-term partnerships, and ensuring that new facilities in emerging markets operate safely, efficiently, and to a consistently high standard. The foundation has been laid. The systems are running. And Monometer continues to lead with evidenced capability, not claims.

For more information contact c.hall@monometer.com

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PECM Issue 78

®®

UK's largest largest distributor distributor UK's

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TOOLS, PLANT & EQUIPMENT

BEYOND CONNECTIONS SPELSBERG

WAGO demo unit shows interconnection and automation expertise WAGO is a name long associated with manufacturing compact and easy to use electrical spring connection technology, but to present its interconnection and automation range, it needed a new demonstration unit. Partnering with enclosure manufacturer Spelsberg, WAGO selected a housing that would enhance the presentation of its broad offering. Crucially, the enclosure would also help to display the advantages of its products in a real-world setting. Clare McCusker, National Sales Manager, Spelsberg UK, explains Wago’s requirements. When people hear the name WAGO, they often associate it with electrical connections, such as DIN railmounted terminal blocks. Although the German brand has a long history in the electrical interconnection field, WAGO also has a wide range of electronic interface products and automation technology. This includes products such as signal conditioners, relays, and voltage converters, as well as I/O systems, controllers, and HMIs. However, WAGO’s position as the market leader in electrical interconnection heightens the challenge to educate customers about its capabilities in electronic interface and automation technology. This is the reason behind the development of its latest demonstration case. Aimed at OEMs, panel builders and switchgear builders, as well as distribution partners and wholesalers, the demo unit presents the breadth of WAGO’s offer to industry. Intended for presentation at customer sites, as well as display at exhibitions, the demo case had to be

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PECM Issue 78

WAGO’s demo unit mounted in a Spelsberg GTi-3 enclosure with a transparent lid, showcases a selection of WAGO’s most outstanding products.

sufficiently compact and lightweight to enable mobile transportation.

and Ireland’s Product Manager for Interconnection.

Real-life product presentation

The demonstration enclosure includes rail mounted terminals, alongside relays, a power supply, and an energy monitoring meter, while automation products include an I/O system and a network switch. The array presents highlights from WAGO’s full range and capabilities, rather than a scale representation

“Installing demonstration products in an industrial enclosure means customers can see how they would look in an actual application, and how they would fit in a control cabinet or enclosure,” says designer of the demonstration unit, Clive Humphrey, WAGO UK

of an actual installation. However, mounting the products within an enclosure helps demonstrate the key advantages of WAGO’s offering. “Our customers require reliable connections and quality products that perform, long-term, in industrial conditions. The demonstration enclosure helps to show that build quality,” explains Clive. “However, another important customer need is small footprint, so products included in the demo case, such as the triple-deck terminal block, which takes the same space along the DIN rail as a standard single terminal, helps demonstrate the compact dimensions of our products.”

Ease of use A further vital need of WAGO’s customers is ease of use. This is answered by features such as leveroperated terminals that enable rapid access for installation. Selection of the enclosure was important to emphasise these key advantages, and the product chosen for the job was a Spelsberg GTi-3 housing with a transparent lid. “All the components in the enclosure are DIN rail mounted,” says Clive. “A key reason I chose this enclosure is because the DIN rail is so easy to fit, with wide flexibility over mounting positions.” Constructed from high strength polycarbonate, the GTi-3 is lightweight for easy transportation. While it’s compact, it is sufficiently deep to house taller products, such as the I/O and triple-deck terminals. “For installation, everyone’s looking to make life easier and complete jobs faster, so features that enable this are important. When mounting an enclosure like this for real, its knockout holes, which show the flexibility available for cable entry and exit points, mean simple installation of cables and glands,” says Clive.

Customisation options While WAGO tends to customise solutions in-house as part of the turn-key service it offers to large

The WAGO demo unit is intended to be presented at customer premises, as well as being displayed at trade fairs and exhibitions.

effective, and accountable compared to involving a third-party.

The enclosures are consistently manufactured to a very high standard, and the support provided by the UK team is very helpful. OEMs, original products that enable rapid customisation is an advantage to WAGO. “Even though Spelsberg can offer CNC machining to drill holes, the flexibility of Spelsberg enclosures means that the design lends itself to fast, straightforward customisation, and this is a real benefit,” adds Clive. For the demonstration unit, WAGO did require Spelsberg’s in-house printing, which included the addition of a colour logo on the enclosure lid. Along with the finish quality, this service is more reliable, cost-

This latest WAGO demonstration unit is the third in a series, all of which use a Spelsberg enclosure. For its customer projects, WAGO also typically chooses Spelsberg as its preferred enclosure supplier. The relationship between WAGO UK and Spelsberg UK has existed for nearly 30 years and began following the original partnership that existed between the two German manufacturers.

Partnership “We enjoy an excellent relationship with Spelsberg,” explains Clive. “The enclosures are consistently manufactured to a very high standard, and the support provided by the UK team is very helpful. Spelsberg UK doesn’t just have a warehouse, it has a facility with engineering expertise in design and customisation, so if we ever have any special requests, the team can quickly provide it, instead of having to wait for support from overseas.”

For further information, please visit www.spelsberg.co.uk Issue 78 PECM

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TRAINING & RECRUITMENT

AI THAT EMPOWERS PEOPLE FELDELUXE

Get AI to do your admin, but not all of it Artificial Intelligence is changing how we work, and it’s easy to see why. The efficiency it brings to repetitive and time-consuming tasks is undeniable. From automating data entry to generating reports and managing communications, AI can help organisations save hours each week. It should not be ignored - in fact, it’s here to stay. But just as important is what AI should not do: replace good people. Your team is more than a collection of tasks, they bring creativity, empathy, and judgment that no algorithm can replicate. The real opportunity lies in using AI to empower people, not replace them. By combining human intelligence with AI’s capabilities, you create an agile, confident, and futureready workforce. Building a positive relationship between your employees and AI is now a tactical advantage. When people feel confident using new tools, they can focus less on small administrative tasks and more on meaningful, high-value work. The key is balance, letting AI handle the repetitive, while your team focuses on the strategic and human side of your organisation. A great way to start is by introducing AI tools in a supportive, learningfocused environment. Encourage your team to experiment, share their discoveries, and find tools that genuinely help them work smarter. You might be surprised to learn that many of them already use AI informally. By formalising this and involving them in choosing what tools to adopt, you’ll build ownership, trust, and confidence, making the transition smoother and more effective.

At Feldeluxe, we’re not an AI company, we’re a people and project management company. At Feldeluxe, we’re not an AI company, we’re a people and project management company. Our mission is to open opportunities for individuals, organisations, and everyone in between that they might not have known existed. Through our project management

services, we help organisations evolve with confidence, focusing on efficiency, culture, and achievement. We improve efficiency by reducing time, effort, or cost in everyday operations. We strengthen workplace culture by improving internal systems and representing your organisation’s values externally. And we support achievements, from securing grants and accreditations to entering new markets. AI is a tool. People are the foundation. Feldeluxe helps you get the best of both, unlocking smarter, sustainable growth that lasts.

For further information, please visit www.feldeluxe.com

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Standard Operating Procedures

Project Management

Admin Services

www.feldeluxe.com 07562 614867 Info@Feldeluxe.com Feldon Haynes

Fostering culture, Gaining achievements, Improving efficiency

TRAINING & RECRUITMENT

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

Alarm systems: A guide to design management and procurement

Recommendations for refrigerated liquefied gas storage tanks

Refrigerated Liquefied Gas Storage Tanks E-Learning

TRAINING & RECRUITMENT

Innovative lean, manufacturing engineering and manufacturing solutions Revicon Solutions Ltd, based in the East Midlands, is a specialist consultancy in Lean Manufacturing and Manufacturing Engineering. We work closely with organisations to tackle long-standing challenges and deliver practical, innovative solutions that drive measurable results. Our mission is to help businesses unlock their full potential through proven methodologies and tailored strategies aligned with their goals. With over 27 years of experience in global manufacturing, we bring expertise across sectors including fabrication, machining, and assembly. This knowledge enables us to understand complex manufacturing environments and provide actionable insights. At Revicon Solutions, we leverage Lean behaviours, tools, and strategic deployment to streamline operations,

reduce waste, and boost efficiency. We have supported businesses of all sizes— from SMEs to multinationals—in achieving sustainable growth and operational excellence. Our experience includes designing and building new facilities, managing work transfers, establishing supply chains, and resolving critical supplier issues. We pride ourselves on delivering solutions that are both innovative and practical. Whether your objectives involve reducing lead times, improving product quality,

empowering your workforce, or increasing value-added activities, Revicon Solutions is here to help. We work collaboratively with your teams to ensure improvements are implemented effectively and sustained over time. Our passion for manufacturing excellence is matched by our commitment to customer satisfaction. If you’re ready to take your operations to the next level, visit Reviconsolutionsltd.com or call 07388 236940. We look forward to partnering with you to achieve your goals.

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Issue 78 PECM

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TRAINING & RECRUITMENT

RECRUITMENT IN 2026 Redefining talent for the engineering sector By 2026, recruitment in the engineering sector has moved far beyond the traditional hunt for degrees, years of experience, and rigid job titles. What defines successful hiring today is adaptability—both from employers and candidates—in a landscape shaped by rapid technological change, global competition, and shifting workforce expectations. Engineering recruiters now operate in a market where skills age quickly. Artificial intelligence, automation, digital twins, renewable energy systems, and advanced manufacturing have transformed what it means to be an engineer. As a result, companies increasingly prioritize capability over credentials. Micro-credentials, project portfolios, and demonstrable problem-solving skills often outweigh formal qualifications. The question is no longer “Where did you study?” but “What can you build, improve, or optimize right now?” Remote and hybrid work have also permanently reshaped recruitment. In 2026, engineering talent is truly global. Organizations routinely recruit across borders, leveraging distributed teams to address skill shortages while increasing diversity of thought. This has intensified competition for top engineers, forcing employers to differentiate themselves not just on salary, but on purpose, flexibility, and career development. Engineers want meaningful work—projects that contribute to sustainability, infrastructure resilience, healthcare innovation, or climate solutions. Another defining feature of recruitment in 2026 is the integration of AI into hiring processes. Intelligent screening tools, skillsmatching platforms, and predictive

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Artificial intelligence, automation, digital twins, renewable energy systems, and advanced manufacturing have transformed what it means to be an engineer. analytics have streamlined recruitment, reducing time-to-hire and unconscious bias when used responsibly. However, the human element remains critical. Successful engineering recruiters understand that cultural fit, collaboration, and ethical judgment cannot be fully automated. Technology supports decisions; it does not replace them. Upskilling and reskilling have become central to recruitment strategy. Rather than endlessly

searching for “unicorn” candidates, engineering firms invest in training pipelines, partnerships with universities, and internal mobility programs. Hiring managers increasingly recruit for potential, confident that structured learning ecosystems can close technical gaps. Finally, employer reputation has become a decisive factor. Engineers in 2026 research companies as thoroughly as companies research them. Transparency around leadership, project impact, diversity, and work-life balance directly influences hiring outcomes. In a candidate-driven market, trust is currency. Recruitment in the engineering sector in 2026 is not just about filling roles—it is about building resilient, future-ready teams. Organizations that embrace flexibility, continuous learning, and human-centered hiring will not only attract top engineering talent, but retain it in an era where innovation never stands still.

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

VALVES & FLOW CONTROL

PUSHING FLOW LIMITS TITAN ENTERPRISES

Titan Enterprises develops bespoke calibration rigs to pioneer ultrasonic ultra-low flow measurement Titan Enterprises has released a technical paper detailing how the company overcame calibration constraints encountered during the development of ultrasonic flowmeters for ultra-low flow applications. With no commercially available systems suited to the demands of its latest R&D programmes, Titan engineered bespoke calibration rigs to support the design, verification, and optimisation of next-generation flow measurement devices. Titan’s production calibration facilities currently incorporate three certified piston provers operating with distilled water from 2 ml/min to 200 l/min, delivering an uncertainty of ±0.05%. These rigs, however, are dedicated to production and could not accommodate the extended testing time, experimental conditions, and extreme flow sensitivities required for the company’s new research initiatives. An additional rig capable of reliably monitoring ultra-low flows was therefore essential. The new calibration rig underpins two major advances in Titan’s ultrasonic technology: 1. an ultra-low flow ultrasonic meter with measurement capability down to 0.2 ml/min or below - extending performance beyond the current Atrato flowmeter; 2. a clamp-on ultrasonic flowmeter designed for disposable medical tubing. The clamp-on system targets small-batch monitoring of medicalgrade fluids used in applications

such as dialysis equipment and bolus drug delivery, where sterile, accurate, and cost-efficient measurement is required. To meet these objectives, Titan developed a miniature piston prover driven by dual synchronised stepping motors with rotational encoders for precise positional control. The rig provides fully computer-controlled flow profiles, bolus simulation, and comprehensive data output. Its design addressed a range of mechanical and hydraulic challenges including system bleeding, valve timing, linear motion stability, drive stiffness, temperature effects, tubing compliance, calibration accuracy, and integrated safety features such as end-of-stroke detection. “This custom-built rig represents a major step forward in Titan’s commitment to precision flow measurement and advancing our R&D capabilities,” says Neil Hannay, Titan’s Senior R&D Engineer. “By

developing our own calibration infrastructure, we’re unlocking new performance frontiers for both industrial and medical flow applications.” The project highlights Titan’s ability to resolve practical R&D barriers through in-house engineering expertise. By controlling its calibration and test environment, the company can accelerate development cycles from concept to validated prototype. Proprietary software facilitates rapid scenario testing aligned with real-world customer conditions, ensuring optimised product performance. The principles established in this calibration rig will guide future development of specialised tools and innovative fluid test units tailored to customer-specific requirements. For the full technical paper, visit Titan’s website or contact sales@flowmeters.co.uk.

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

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Ultrasonic Flowmeters

Turbine Flowmeters

Innovative Liquid Flow Measurement Solutions Titan Enterprises is a leading design and manufacturer of innovative end user and OEM high-performance flowmeters and flow measurement instrumentation, used within a wide range of processes, environments and applications. • Compact, robust, reliable • Excellent accuracy and repeatability • Measure low to high flow ranges

Oval Gear Flowmeters

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VALVES & CONTROL

TECHNOLOGY INNOVATION GEMÜ

GEMÜ D41 diaphragm valve with EasyLock homogeneous flow characteristics. This enables the GEMÜ D41, as well as the GEMÜ D40 diaphragm valve already announced, to achieve up to 100% higher Kv values. The pioneering products of the GEMÜ LEAP product generation not only include the GEMÜ D41, but also three further valves and two automation components:

The valve manufacturer GEMÜ, the global market leader in the valves, measurement and control systems sector for sterile applications, has developed a new valve product as part of its new product generation. The GEMÜ D41 diaphragm valve features EasyLock technology. This enables maintenance in seconds, reduces complexity and makes handling diaphragm valves significantly easier. GEMÜ is thereby reshaping the future of valve designs The pneumatically operated GEMÜ D41 diaphragm valve is designed for use in aseptic manufacturing sectors. The sealing concept of the valve is based on the newly developed GEMÜ diaphragm, which also hermetically separates the actuator from the working medium. GEMÜ D41 with EasyLock technology is installed entirely without loose components via a central gearbox. The GEMÜ D41 diaphragm valve with EasyLock technology is easy to handle, safe to use and effective in its process. EasyLock technology offers not only more reliable installation, but also an even compression of the diaphragm. The actuator is fixed to the body via a bayonet fitting and then centrally tensioned via a gearbox entirely without any loose components using an outer hexagon. This makes actuator mounting and disassembly, commissioning and diaphragm replacement significantly simpler and quicker. Furthermore, the diaphragm with bayonet pin facilitates

GEMÜ D40 – the high-performance, pneumatic diaphragm valve GEMÜ S40 – the pneumatic globe valve with angle seat and straight seat designs GEMÜ P40 – the efficient tank bottom valve with PD technology GEMÜ 12A0 – the intelligent electrical position indicator

The GEMÜ D41 diaphragm valve with EasyLock technology is easy to handle, safe to use and effective in its process. diaphragm replacement, while the new diaphragm technology offers greater safety and precision in plants. Due to the new seal system with fixed chambering, the natural setting behaviour of the diaphragm is controlled such that it is no longer necessary to retighten the diaphragm. The optimized rolling behaviour of the diaphragm provides better controllability and ensures low stress on the diaphragm, meaning that maintenance intervals can be optimized to specific applications. The new body design not only saves weight but also ensures a high flow and

GEMÜ 44A0 – the multi-functional combi switchbox Throughout 2026, GEMÜ Great Britain are running a nationwide roadshow, giving customers the chance to explore the new innovations up close and discover how they can enhance applications. You can book a demo visit by emailing: customer.support@gemu.co.uk

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

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VALVES & CONTROL

Precision flow technology to keep your operations running smoothly

DIN11864 and 11853 unions were developed to meet the

Delta Flowtech have been working together to provide solutions for the accurate and reliable measurement of water, waste, chemicals and food products with our customers for over 35 years Optimize your operations with flow measurement technology engineered for accuracy, durability, and seamless integration. Our large range of flow meters deliver: • Exceptional Precision – Real-time, reliable measurements for even the most demanding applications.

DIN11864 and DIN 11853 Aseptic Unions for Orbital Welding exacting needs of the food, chemical and pharmaceutical industries. This range of unions has been developed from the three most common systems used in the hygienic and sanitary industries; namely the “Aseptic” screwed union to DIN118641; the “Aseptic” flange union to DIN11864-2 and the “Aseptic” clamp union to DIN11864-3. Available with optional lengths to suit both orbital and manual

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Oliver Valvetek wins OneSubsea “On-Time Delivery” Supplier Award in Norway Oliver Valvetek has been recognised by Schlumberger OneSubsea with the Best Supplier – On-Time Delivery Award, presented at the annual OneSubsea Supplier Day in Oslo. The award marks the second time in three years the company has received this distinction, highlighting its consistent reliability in subsea valve supply. The Oliver Valves Group was represented at the event by Daniel Oliver and Colin Wood, alongside senior figures from OneSubsea’s global supply chain, including Victor Ferreira, Robert Chenery, and Daniel Hayles. This year’s Supplier Day focused on the new subsea era, exploring innovation, supply chain efficiency, and collaboration across major global energy projects. OneSubsea shared market insights covering key operators such as Equinor, Chevron, Woodside, Petrobras, TotalEnergies, Eni, ExxonMobil, and CNOOC, outlining expected growth across oil, gas, and LNG markets through to 2030. Innovation and cost efficiency, while maintaining the highest performance standards, were central themes throughout the day. OneSubsea reaffirmed its confidence in Oliver Valvetek’s product quality, communication, and responsiveness, highlighting the strength of the long-standing partnership. Discussions also explored future product development, expanded global manufacturing capabilities, and opportunities to broaden subsea valve offerings. The award reflects the dedication of the Valvetek (TEK) team and their reputation for dependable, high-integrity subsea engineering.

Commenting on the award, the team said: “This recognition is a testament to the dedication of our people and their commitment to meeting the toughest subsea demands. With teamwork, precision and British engineering expertise, It Can Be Done.”

www.valves.co.uk Issue 78 PECM

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INSPECTION EQUIPMENT

SHARPER, SMARTER 3D VISION ENGINEERING

Vision Engineering redefines collaborative inspection with debut of ProteQ VISO at Southern Manufacturing & Electronics (Stand G240) Vision Engineering, a leading global manufacturer of ergonomic inspection and non-contact metrology systems, today announced its participation at the Southern Manufacturing and Electronics trade show, taking place from 3–5 February at the Farnborough International Centre. The company will exhibit its full range of award-winning technology, headlined by the highly anticipated debut of the ProteQ VISO digital stereo inspection system at Stand G240. The new ProteQ VISO system is set to be the key attraction, introducing a breakthrough in digital stereo inspection. It delivers a high-quality, authentic 3D image viewable comfortably on a flat screen. Crucially, the ProteQ VISO includes the innovative capability to securely and instantly share this high-fidelity 3D inspection view with other users, enabling unprecedented levels of remote collaboration and collective decision-making across quality teams. Visitors to Stand G240 will have the opportunity to experience Vision Engineering’s renowned, patented eyepiece-less technology first-hand. Featured inspection products will include the latest Mantis 3rd Gen, the Queen’s Award-winning Lynx EVO, and the ultra-high-definition EVO Cam HALO 4K inspection systems. Beyond inspection, the stand will host an extensive display of Vision Engineering’s precision metrology solutions, including the versatile LVC series, the robust Deltron CMM, and the high-speed Swift PRO EDGE

zoom non-contact measurement system. Vision Engineering encourages all trade show attendees, particularly quality managers, design engineers, and production specialists, to bring their own samples. The team will provide personalised, hands-on demonstrations using their advanced technology range for both inspection and measurement tasks. Visit Vision Engineering at Stand G240, 3–5 February, Farnborough International Centre.

W: www.visioneng.com

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T: 01483 248300

E: enquiries@visioneng.co.uk