Process Engineering Control & Manufacturing Issue 33 2018

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Engineering Process

Control &



Global Success Through Innovation Issue 33 2018 £3.95



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Allowing the UK robotics industry to embrace opportunity.

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Engineering Process

Sections Editors Choice Air, Gas & Odour Control Automotive Engineering Boilers & Maintenance Control & Automation Electrical & Electronics Facilities Management Fluid Handling Gears, Drives & Motors Health & Safety Hydraulics & Pneumatics Industrial Cleaning Machining & Machinery Measurement & Monitoring News & Events Process Technologies Product News Software & Systems Storage, Handling & Distribution Switches & Sensors Valves & Flow Control


Control &


Inside Issue 33 6 36 40 44 48 54 65 70 78 80 84 87 88 93 104 109 115 117 121 125 126

ALUMINIUM ALLOYS IN THE AEROSPACE INDUSTRY Aluminium has a long and successful history in the aerospace industry. As far back as the 19th century, Count Ferdinand Zeppelin made the frames of his iconic airships from it. ANNUAL PHOTOGRAPHY COMPETITION PUTS BRITISH MANUFACTURING IN THE FRAME Photographers of all experience levels are being asked to capture the dynamism of modern British industry as the 9th annual EEF Manufacturing Photography Competition opens for entries.

REDUCE WASTE AND FUTUREPROOF PRODUCTION WITH AUTOMATIC PRODUCT RECOVERY It seems that everybody is talking about Industry 4.0. Whether you are reading a magazine, visiting a trade show or talking to business consultants, it doesn’t take long for the latest manufacturing buzzwords of ‘Industry 4.0’, ‘fourth industrial revolution’, or ‘internet of things’ to be mentioned. SULZER UNVEILS 2018 INTERN PROGRAM Investment in new staff is very important for the continued success of a company. It is essential to find the most suitable prospects to train and set on the road to a career in engineering.

Issue 33 PECM


Engineering Process

The leading source for innovators in Technology, Manufacturing and Maintenance within the Engineering & Processing industry worldwide. Published bimonthly, a subscription to PECM magazine is essential for Process Engineers, Chemical Engineers, Instrumentation Engineers, Mechanical Engineers, Plant Engineers, Precision Engineers, Environmental Engineers & General Engineers, Companies and Organizations in the Food, Dairy, Beverage, Brewing, Semiconductor, Pharmaceutical, Biotechnology, Chemical, Oil & Gas, as well as all UK's major manufacturing units. Every issue of the magazine contains the latest news, in-depth features, together with product innovations and case studies showing how process engineers are implementing new technologies to reduce costs and impact on the environment. With over 300,000 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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Issue 33 PECM




SYSTEMATICALLY INNOVATIVE ENCLOSURES After five years of development work, Rittal has unveiled its new VX25 large enclosure system at the 2018 Hanover Trade Fair.

He added that: “The new Rittal large enclosure has now become 100 percent Industry 4.0-capable.

emerged, providing developers and product managers with a robust guide for the actual development work.

It is the first enclosure system that has been fully developed to meet the requirements for increased productivity in control and switchgear manufacturing, as well as along the Industry 4.0 value chains.

With the combination of a real enclosure and its digital twin, the new development will meet every future digitization needs – from online configuration and engineering to assembly, as well as automation, logistics and maintenance.”

Rittal supplemented its findings with those of the customer advisory council (who were also involved).

With the “SYSTEM PERFECTION.” slogan, Rittal has made a major innovative leap; a leap which has come from its depth of experience, as well as intensive customer feedback and involvement. The VX25 offers the highest possible quality and consistency of data, reduced complexity and savings in time, as well as safe assembly. More than 25 registered patent and trademark applications demonstrate the high level of innovation that was involved. How can the best be made even better? This is the question that Rittal asked itself as it began developing a new enclosure system. “The market needs an enclosure that cuts throughput times in engineering and assembly, reduces complexity and that finds a place for itself as a full-grown module in the megatrend of digitisation,” said Dr Thomas Steffen, Managing Director Research and Development at Rittal.

Later, during the development phase, Rittal did not omit one single, essential point.

Study: observe, listen and learn Intensive dialogue with Rittal customers was a crucial factor in the development of the new large enclosure system. During a large-scale, scientifically based, usability study, researchers used words, images and moving film to document the everyday working life of control and switchgear manufacturers, covering ten companies in Germany, eight in the USA and six in China, including small, medium-sized and large companies. “This user analysis was an eye-opener. In some cases, we spotted problems that the customers themselves hadn’t yet identified,” said Dr Steffen. As a result, 150 systematically recorded and specific requirements for a new enclosure




The Result: Pure Customer Benefits! The result was the new VX25 large enclosure system. The name VX25 stands for three elements: the versatility of options; the fulfilment of “x” customer requirements; and for its perfect symmetry through a consistent 25-mm pitch pattern. “What is new is that no enclosure system has ever been previously developed so consistently and systematically to ensure maximum customer benefit. The VX25 matches the way the control and switchgear manufacturer thinks and works – both in functions and processes,” says Dr Steffen. Customer benefits across the entire value chain of control and switchgear manufacturing can be summarised in three key points: maximum data quality and a constant supply of data; reduced complexity and savings in time; as well as safe assembly.

Patents: a high degree of innovation The heart of the innovation is the newly developed frame section. This determines the installation space, the efficiency in engineering and assembly, the expansion options, the stability and thus the reliability and flexibility in the customer’s workshop. With the new large enclosure system, Rittal’s engineers could maintain all the important and established product features of the existing, worldwide TS 8 large enclosure system, expanding them significantly with a multitude of new functions and customer benefits. There were more than 25 registered patent and trademark applications, which demonstrate the high level of innovation in the VX25.

Production: Maximum Quality For Rittal, SYSTEM PERFECTION also involves high-tech manufacturing. It has invested in new state-of-the-art production facilities to manufacture the new frame section of the VX25. New and fully automatic profiling systems and volume production lines, with a total of 31 welding and handling robots, are witness to the focus on top quality combined with precision and stability. The result is that the frame section of the VX25, which has a consistent 25-mm pitch pattern, is clearly more stable than its TS 8 predecessor, although the weight is the same.

Further information at and or on twitter @rittal_ltd.

VX25. SYSTEM PERFECTION. More More options, options, more more efficiency, efficiency, less less effort: effort: This This is is thanks thanks in in particular particular to to aa frame frame profile profile with with aa 25 25 mm mm pitch pitch pattern pattern that that is is symmetrical symmetrical across across all all levels. levels. The The VX25 VX25 is is also also infinitely infinitely extendable extendable and and accessible accessible from from all all sides sides –– even even from from the the outside. outside.





ALUMINIUM ALLOYS IN THE AEROSPACE INDUSTRY Aluminium has a long and successful history in the aerospace industry. As far back as the 19th century, Count Ferdinand Zeppelin made the frames of his iconic airships from it. Aluminium was chosen as it is lightweight, strong, and has a high resistance to corrosion. In this article, Marta Danylenko, marketing manager at online materials database Matmatch, explains the common alloys used in aerospace engineering and their applications, as well as some less wellknown ones, and what the future holds for aerospace materials.

A brief history The Wright brothers chose aluminium for the cylinder block and other engine parts for their first manned flight in 1903. It was also the first time an aluminium alloy had been heat-strengthened. This discovery prompted the preference for aluminium in aerospace engineering. Over the years, the aerospace industry has become more demanding in what it needs from materials. The advent of jumbo jets and long-haul international flights meant that the shell and engine parts had to be extremely durable and resistant to fatigue. This has led to the development and use of many different types of aluminium alloys.

Commonly used aluminium alloys in the aerospace industry Second only to AA 2024 in terms of its popularity in aerospace engineering, AA2014 is a strong and tough metal and is suitable for arc and resistance welding. However, it has poor corrosion resistance, and for that reason, it is often found in the internal structure or framework of aircraft rather than the shell. Aluminium alloy 2024 is probably the most widely used alloy for aircraft. It was developed after experiments allowing small amounts of cold deformation and a period of natural ageing led to an increased yield strength. 2024 is a high-grade alloy with excellent fatigue resistance. It’s used primarily in sheet forms such as for the fuselage and wings due to its high tensile strength of roughly 470 MPa. Of the nonheat treatable grades of alloy, AA 5052 provides the highest strength and is highly ductile, so it can be formed into a variety of shapes including engine components and fittings. It is also highly corrosion resistant.


PECM Issue 33

AA 6061 alloy is very common in light aircraft, especially homemade ones. It’s easily welded and manipulated, is very light and fairly strong, making it ideal for fuselage and wings. AA 7050 has high corrosion resistance and maintains strength in wide sections. This makes it more resistant to fractures than other alloys. It’s commonly used in wing skins and fuselage, especially in military aircraft. AA 7068 is the strongest alloy available today. Combined with its low mass, it is perfect for military aircraft that need to stand up to tough conditions and attacks. With similar strength properties to steel due to its high levels of Zinc, AA 7075 has excellent fatigue resistance. It can be machined easily which meant it was a popular choice for fighter planes in World War II, including the Mitsubishi A6M Zero fighter used by the Japanese Imperial Navy on their carriers between 1940 and 1945. It is still used frequently in military aircraft to this day.

Less common aluminium alloys in the aerospace industry If you need an aluminium alloy that provides maximum strength at elevated temperatures, AA 2219 is the best bet. It was used for the external fuel tank of the first successfully launched space shuttle, Columbia. It has good weldability, but the welds need heat-treating to preserve resistance against corrosion.

AA 6063 is mainly used for aesthetic and architectural finishes and can be found in the finer details of an aircraft. It is used primarily for intricate extrusions. AA 7475 is highly resistant to fracture and fatigue. Due to its toughness, it is sometimes found in fuselage bulkheads of larger aircraft.

The future of aluminium alloys in aerospace Industry experts are positive about the future of aluminium alloys in aerospace. It is projected that demand for aluminium will double over the next decade. By 2025, there will be a global demand of 80 million tonnes. For this reason, the aerospace industry is increasingly looking to recycled alloys to satisfy their high demand. There is also a push for innovation in the materials used, as well as the design structure of aircraft. As developing countries become more involved in the aerospace industry, and with increased investment, there will be further innovation in aluminium alloys over the years to come. If you’re looking for a tool to compare engineering material properties, Matmatch’s online database helps you to find materials, compare them side-by-side and choose materials that perfectly fit the intended application, the budget for the project and your goals.




Photographers of all experience levels are being asked to capture the dynamism of modern British industry as the 9th annual EEF Manufacturing Photography Competition opens for entries.

event in London in November. Winning photographers will get their hands on a share of a £5000 prize fund and be in with the chance of having their photos on display in the national and local media.

This year the competition - in partnership with the GREAT Campaign - is asking photographers to capture the bright future of British Manufacturing and champion the next generation of talent and technology in the sector. Photographs can portray any stage of manufacturing - from design, process and technology in action through to the finished product – and feature individuals at work.

To give entrants the best shot at winning, companies are being urged to open their doors to local photographers. For information on how to do this, visit the

There are four categories for photographers to enter: Next Generation, Future Technology, Manufacturing Process and Manufacturing Product. The competition is free to enter and open to young, amateur and professional photographers alike. Entries will be shortlisted by a panel of photography and industry experts, with winners announced at an awards


PECM Issue 33

The Rt Hon Dr Liam Fox MP, Secretary of State at the Department for International Trade, says: “We are delighted to support EEF’s photography competition which offers a fantastic opportunity for participants to showcase the technology, dynamism and energy of modern British industry and manufacturing, which has played a huge role in seeing UK exports grow by 9.2% to £628bn over the past year. The competition closes for entries on Sunday 30th September. For more information and to enter the competition, visit

Stephen Phipson CBE, CEO at EEF, says: “The Manufacturing Photography competition shines a light on our forward looking and innovative industry. It celebrates the people and the products that help make manufacturing the beating heart of the UK Economy. I wish all the photographers that enter the competition the best of luck and cannot wait to see the entries when they go on display at the awards event later in the year.” “As an international economic department, we are on hand to help UK companies to forge new global trading ties that will boost trade, drive growth and provide jobs to every part of the country.”

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Issue 33 PECM




Cross & Morse Torque Limiters are low cost protection devices that limit torque in a drive system in order to:• •

Prevent machine and drive damage. Eliminate costly machine downtime.

The Morse Torque Limiter limits torque transmitted in a drive system by slipping when a preset value is exceeded as a result of shock load, overload or machine jam. It automatically re-engages, when the overload is removed, no re-setting being required. Torque is transmitted by spring loaded friction faces, the value being preset by adjustment of the spring force by simple setting of the adjustment nuts and bolts. The Torque Limiter is suitable to use with sprockets, gears, pulleys or a flange plate as the centre member is clamped between the friction facings. The Torque Limiter can accommodate shaft sizes of 5mm to 120mm (3/16 to 4.5”) and torque ranges of 3Nm to 10,000Nm (2.2 to 7375 lbs ft)

The Torque Limiter is not a new product with Cross & Morse. In 1949 Morse introduced the first spring loaded, friction type protective device which was developed to suit today’s line of products consisting of 7 sizes, the models 200M to 700M being the most popular units. To further extend the capabilities of our products a new metric series of clutches, consisting of 6 sizes from M30 to M280 has been added, to cater for higher torque applications, and areas where space is limited. As the originator of the Torque Limiter, Morse gained vast experience in the design and application of these units as trouble free and long lasting protective devices.

Many thousands of units have been fitted to conveyors, mechanical handling equipment and agricultural machines proving the reliability of the product.

Cross + Morse

Power Transmission Manufacturing Specialists in the UK Since 1984

◊ Manufacturing up to 1450mm diameter ◊ Turning - CNC lathes, Vertical Machining Centre ◊ Gear Cutting - Hobbing, Planing, Shaping Gears ◊ Bevel Gears, Helical, External & Internal cut Spur Gears ◊ Worms & Worm Wheels ◊ Rack Shaping, Broaching, Keywaying ◊ Vertical Boring, Centreless & Rotary Grinding ◊ Bore Honing ◊ Induction Hardening ◊ Drilling & Tapping ◊ Large stocks of Transmission Drive components ◊ CAD - CAM Design & Development

Yes we can make it.

Cross + Morse. Shady Lane, Great Barr. Birmingham. B44 9EU Tel: +44 (0)121 360 0155 Fax: +44 (0)121 325 1079


PECM Issue 33

EXVERITAS OFFER A FREE VERSION OF THEIR CLOUD-BASED DSEAR EX INSPECTION AND ASSET MANAGEMENT SOFTWARE WE BSOFT ExVeritas have created a free fully functional version of their industry leading intelligent Ex inspection and management software iEx Inspection ® iEx Inspection is the worlds first ‘intelligent’ Ex Inspection system. Once an inspection area has been defined, the system will warn you if you try and install equipment which doesn’t have the correct ATEX or IECEx specification. The system will also intelligently select the appropriate Ex inspection questions (which can be fully customised) based on the type of inspection and Ex equipment protection concept. In addition to this, the system controls inspector competence, allocation and scheduling of the inspections, remedial work priority and sign off and full reporting, including analytics of defect types.

The free version is limited to 50 items of equipment but has full cloud back up and full Android tablet input support (the Android application that enables inspectors to input inspection data via a handheld tablet is also free). Sean Clarke, MD of ExVeritas Limited, said ‘There are many smaller sites that struggle with Ex inspection compliance and don’t have the time or money to set up suitable asset and inspection management systems, we have created this free version to try and help these industries achieve a safer working environment at no cost whatsoever’ Although iEx has a lot of built in intelligence in the free version, there is always the occasion when you may need a second opinion. On paid subscriptions (for larger sites with many more items to inspect and manage) the ‘ask the expert’ button on the software immediately links your inspection enquiry to our ‘real’ team of verified experts!


About ExVeritas ExVeritas is an ATEX Notified Body and IECEx Certification Body providing internationally recognised product certification for global markets together with the necessary Quality System Certification including UKAS accredited ISO9001:2015. For manufacturing and industrial sites we offer safety consultancy on DSEAR (including area classification, design, installation, inspection and risk assessment) PUWER and PSSR. We also offer accredited training and competence certification for CompEx and API Q1 and Q2 personnel together with specialist and bespoke training.

Manage Your Ex Inspection Intelligently with 'iEx'. Designed and supported by Experts. iEx inspection is the most intelligent and flexible hazardous area 'Ex' inspection and management system available...but don’t take our word for it, you can simply log in and use a FREE fully functional version of iEx immediately. is developed and supported by ExVeritas Limited

Issue 33 PECM





Options include a tool tray and a Vehicle maintenance and production gate cancentres be require fittedengineers to the system. to work at height and ensure the smooth running and fulltime operation of the plant. And it can be stored in a LOBO Awkward and restricted access areas Towerstore unit when not in use. present additional hazards when working at height and maintenance tasks must routinely be performed where access is extremely difficult.

Areas where, typically, standard working at height equipment cannot fit and does not sufficiently adjust.

LOBO is a rigid and stable management begins an product,Safety which meets orwithexceeds organisation ensuring that employees nternational regulations. have fit forsafety purpose, work at height safety equipment, on which they have been trained to assemble, inspect and use safely.

Access equipment which is unstable or rickety, which does not fit properly and is therefore dangerous, should never be used.

LOBO Systems provides fully certified training for safe assembly, inspection and use.


EU: BS EN1004:2004 BS 1139 parts 3 & 4, USA: OSHA Compliant, ANSI A10.8, 29 CFR Part 1920 (General Industry) Canada: CSA Z797-09 and 269.2 (M87 and -16) Australia: AS/NZS 1576.1:2010 and AS/NZS 1576.3:2015 Tower


PECM Issue 33

The LOBO Advanced Platform is the solution

Sway braces, toe boards, wheels, handrails, outriggers and a lifting slider beam can be added to enhance the construction.

The LOBO System is a versatile work platform product that combines the flexibility and strength of traditional scaffolding with the simplicity and mobility of tower systems.

The LOBO System is scalable, adaptable and adjustable to meet your on-going and changing requirements.

The unique and patented hand adjustable clamp, when combined with the tube, allows the engineer to create a work platform, of any shape or size, without the need for any tools. The system is made from modular steel components, which are easy and quick to assemble and provide a rock steady and safe working platform. It flat packs for transportation and yet is incredibly strong. Areas previously awkward to get to, can now be accessed by your own engineers or technicians with ease, whenever required.

Simply add more components or alter your existing configuration to satisfy the demands of the next task. Protect your initial investment with a product that will meet all your access needs safely! The LOBO System can be transported and assembled fast and with ease from a flat pack, into any required configuration, by your own maintenance engineers and technicians. Options include a tool tray and a gate can be fitted to the system. And it can be stored in a LOBO Towerstore unit when not in use.

The LOBO System comprises of trestle legs that vary in size and adjustable extensions with fixed side clamps.

LOBO is a rigid and stable product, which meets or exceeds international safety regulations.

Steel tubes can then be passed through the clamps, which are hand tightened to form a structure to suit the application.

LOBO Systems provides fully certified training for safe assembly, inspection and use.

For more information and to arrange a product demonstation please contact us by either email: Telephone: +44 (0) 1332 365666 Issue 33 PECM




Cambridge Sensotec has been supplying gas analysis solutions for 20 years. Based in the UK, the company has an established worldwide distribution network and ISO 9001 accreditation. Specialists in oxygen analysis, we also offer a range of biogas, syngas, multigas and SF6 gas analysis instruments. Contact us today to discuss your requirements.

+44 (0)1480 462142

Hybrid technology from OGM reduces injection mould tooling lead-times by 50%

Bulgin extends 4000 series of miniature circular power connectors

An innovative new service from OGM, a leading UK injection moulding specialist, has been introduced to reduce the lead-time for producing mould tooling by up to 50%. Based on the combination of conventional subtractive machining and the latest additive manufacturing processes, to form a hybrid technology, the new Rapid Production Mould Tools (RPMT) service will help both to compress lead-times and enhance still further the quality and finish of most types of mould tool inserts.

Bulgin has announced the extension of their 4000 series of miniature circular power connectors to meet the growing demand for power connector solutions that are both ultra-small and highly reliable. Adding to the existing 3, 8 and 12-pole solutions the range extension comprises 2, 4, 6 and 10-pole configurations, thereby more than doubling the options available.

Mould tool inserts have traditionally been manufactured using conventional CNC machining techniques. Although these produce high quality inserts, the production time, especially for complex tooling, can be lengthy, the ability to create intricate shapes is limited and the costs are relatively high.

Modern applications demand increased flexibility as well as high power density and reduced weight – all in a small footprint. The 4000 series delivers all of that and is capable of carrying a variety of voltages and currents throughout modern systems. The cost-effective connectors are also highly rugged and suitable for applications where long-term durability is a necessity. |

Robust and reliable manual machine function switching: Herga Technology launches new multi-function industrial footswitch range

JSP is ahead of the Reg!

Herga’s new 6256 series footswitches will suit applications where durability, reliability and long working life are key factors for plant & equipment OEMs and machine builders. Using Herga Technologies unique development gate process, the modern and aesthetic high impact injection moulded ABS/PC housing design has been extensively validated for durability, temperature, environmental conditions and is a significantly cost-effective but highly capable alternative to more expensive castmetal footswitch solutions. Applications areas include operator enabled function switching where hand control is not feasible or safe in metal or plastics processing, laser machining, hydraulic press, welding, riveting stamping and more.

This is a year ahead of the cut-off date of 21st April 2019!

For further details of the new 6256 series visit or email or call +44 (0)1284 701422.

JSP Ltd is pleased to announce that they have on day one of the enforcement of the regulation the vast majority of their product range certified to the new PPE Regulation, 2016/425.

Over 150 products on 15 certificates across the complete range of their above-the- neck PPE offering including their market leading EVO® Industrial Safety Helmet Range and Force™ Respirators will be manufactured in accordance with the new regulation from day one. JSP Ltd has ensured that it is in conformity with the latest European requirements at the earliest opportunity. For further details on the new PPE Regulations please contact them on 01993 826050.

Bulgin launches smallest rugged fiber optic connector Rugged connector and component manufacturer Bulgin has launched a new series of LC fiber optic connectors specialised for use in harsh environments. As the smallest rugged optical connector available on the market, the 4000 Series Fiber Simplex connector is ideal for outdoor broadcast, FTTX (fiber to the x), server room engineering, civil engineering, marine, aviation and rail applications. The connector’s small form factor is particularly useful where installation space is limited or multiple connectors need to be accommodated. Featuring a secure quick twist (30°) bayonet connection, the 4000 Series Fiber Simplex connector accommodates durable mechanical mating. For more information, please visit

The new PPE Regulation states that helmet mounted ear defenders must be properly accredited to the helmet being used Under the new PPE Regulation - and with hearing protection moving to Category III companies and officers of companies face the prospect of fines if helmet mounted ear defenders have not been properly accredited to the relevant helmet in use. Failure to operate such a policy could mean irreparable hearing damage is caused and claims from workforce. JSP’s Sonis® helmet mounted ear defenders are accredited for use with JSP’s EVO® helmet range and can guarantee through rigorous testing that it is the safest hearing protection solution for end users using JSP EVO® range helmets. Peaking at an unbeaten SNR of 36 the Sonis® helmet mounted ear defenders are specially designed to be compatible to work with the company’s EVO® range of industrial head protection.

Issue 33 PECM



Product Technology Partners celebrates 10-year anniversary for LabVIEW user group

Blackburn Chemicals Ltd., a world leader in foam control and antifoaming solutions, has installed a range of Babcock Wanson process heating systems into its Lancashire factory as part of a major expansion programme.

Product Technology Partners (PTP) has announced it will be running its LabVIEW user group events (CLUG) - which provide the opportunity for engineers to grow their expertise in LabVIEW – for a tenth year.

Blackburn Chemicals is a family run company, founded in 1972, supplying a wide range of industries, including paper, food, paint and textiles, in over 50 countries.

PTP runs the free meetings to encourage engineers to discuss common challenges and share experiences and ideas, featuring presentations on different aspects of LabVIEW, customer issues and Q&A sessions. They are part of a series of activities PTP organises to engage engineers from around the country.

The company has been expanding production on site and most recently, since 2015, has invested over £8m on new plant and equipment which will help double production in different sectors.

This includes exhibiting at the National Material & Supply Chain Expo at the Ricoh Arena in Coventry on June 26th and face-to-face visits to engineering companies to run free onehour troubleshooting seminars on LabVIEW solutions during the next two months.

Adelphi Nelsons Spatone have taken delivery of an Adelphi custom stainless steel mixing vessel for their range of liquid iron supplements. The vessel collects cold, iron rich waters from Trefriw Wells Spa. As water collects, it is warmed by a heated jacket around the vessel, and a stirrer keeps the water moving. Once the water is warmed, it is mixed with a flavouring to a batch size of 2,500L. The finished product is then drained from the vessel, ready to be filled and packed. Adelphi are experienced at designing and building custom vessels and tanks for pharmaceutical and healthcare customers. Do you have a similar requirement, or are you looking for a custom built vessel in your factory? Please contact us. T: +44 (0)1444 472300 E: W:

Leaders in bespoke calibration & test systems With over 40 years experience designing and building high integrity test and calibration systems, Chell’s engineers are ready to design complete solutions for your production calibration needs.

Pressure, Vacuum & Gas Flow Automated Product Calibration All Cal. Standards to ISO17025 All Design & Build to ISO9001 Ask your engineers to call our engineers, they almost certainly speak the same language.

Chell Instruments Ltd . +44 (0) 1692 500555


PECM Issue 33

36 Channel Smart Gas Meter Calibration System

伀甀爀 攀渀搀甀爀椀渀最 爀攀瀀甀琀愀琀椀漀渀 昀漀爀 瀀爀漀搀甀挀椀渀最 猀甀瀀攀爀椀漀爀 戀攀猀瀀漀欀攀  氀琀爀愀琀椀漀渀 瀀爀漀搀甀挀琀猀 琀栀爀漀甀最栀 洀漀搀攀爀渀   洀愀渀甀昀愀挀琀甀爀椀渀最 洀攀琀栀漀搀猀 栀愀猀 戀攀攀渀 瀀爀愀椀猀攀搀 戀礀 漀甀爀 挀氀椀攀渀琀猀 椀渀 愀氀氀 椀渀搀甀猀琀爀礀 猀攀挀琀漀爀猀 昀漀爀 ㌀  礀攀愀爀猀⸀ 吀栀攀猀攀 栀椀最栀 焀甀愀氀椀琀礀  氀琀攀爀猀 漀û攀爀 爀攀氀椀愀戀椀氀琀礀Ⰰ 愀爀攀 搀甀爀愀戀氀攀 愀渀搀 洀愀搀攀 琀漀 攀砀愀挀琀椀渀最 猀瀀攀挀椀椀挀愀琀椀漀渀猀 琀漀 猀甀椀琀  礀漀甀爀 愀瀀瀀氀椀挀愀琀椀漀渀 愀渀搀 挀愀渀 戀攀 洀愀渀甀昀愀挀琀甀爀攀搀 焀甀椀挀欀氀礀⸀ 圀栀礀 渀漀琀 氀漀漀欀 愀琀 漀甀爀 䘀䔀䔀䘀伀 爀攀瘀椀攀眀猀 愀琀㨀 栀琀琀瀀㨀⼀⼀眀眀㈀⸀昀攀攀昀漀⸀挀漀洀⼀攀渀ⴀ最戀⼀爀攀瘀椀攀眀猀⼀挀爀漀昀琀ⴀⴀ氀琀攀爀猀ⴀ氀琀搀

䄀刀䔀 夀伀唀 䠀䄀嘀䤀一䜀  䐀䤀䘀䘀䤀䌀唀䰀吀夀 䤀一 伀䈀吀䄀䤀一䤀一䜀  䄀 刀䔀倀䰀䄀䌀䔀䴀䔀一吀 䘀䤀䰀吀䔀刀㼀 伀䰀䐀 䘀䤀䰀吀䔀刀

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䌀刀伀䘀吀 䘀䤀䰀吀䔀刀匀 䰀吀䐀 簀 ㈀ 䈀䔀䔀䌀䠀 䌀伀唀刀吀 簀 吀䄀夀䰀伀刀 䈀唀匀䤀一䔀匀匀 倀䄀刀䬀 簀 刀䤀匀䰀䔀夀 簀 圀䄀刀刀䤀一䜀吀伀一 簀 䌀䠀䔀匀䠀䤀刀䔀 簀 圀䄀㌀ 㘀䈀䰀 琀㨀  ㄀㤀㈀㔀 㜀㘀㘀㈀㘀㔀 簀 昀㨀  ㄀㤀㈀㔀 㜀㘀㔀  ㈀㤀 簀 攀㨀 猀愀氀攀猀䀀䀀氀琀攀爀猀⸀挀漀⸀甀欀 簀 眀㨀 眀眀眀⸀⸀氀琀攀爀猀⸀挀漀⸀甀欀




The importance of monitoring the condition of any given oil should not be underestimated. Oil is the life blood of all hydraulic, engine, plant and rotating machinery. Oil that is either contaminated through water or particulate ingress or is coming to the end of its useful life through additive depletion or excessive oxidation should be monitored closely to avoid costly breakdowns and unnecessary system failures. A survey of over 20,000 oil sample lab results showed that in over 85% of cases oil was being changed at the wrong time by relying on OEM timing intervals rather than via condition monitoring. Introducing the all new Particle Pal Life. Combining a particulate laser counter with a water sensor and an accurate Full Spectrum Holistic oil condition sensor from Tan Delta.


PECM Issue 33

The all new Particle Pal Life gives a portable, real time view of an oil’s condition. Particle Pal Life is controlled and operated via an easy to use tablet app, built into the design. The software shows cleanliness and water levels in real time as well as oil condition/ remaining useful life. All data is logged, can be recalled and added to in order to build up a trend history. Automatic off-site data backup for additional safety and archiving/security of results is also included. Particle Pal Life is an extension of the awardwinning Particle Pal range. Three models cover particulate, particulate and water sensing and now particulate, water and oil life. Suitable for just about any oil or diesel fuel monitoring application the Particle Pal range offers affordable portable monitoring and logging of results.

All Particle Pal’s are portable field kits with their own pump and battery packs. Samples can be drawn from equipment running live under pressure or drawn into the unit via a sample bottle. Viscosities up to 420cst are catered for as standard with higher viscosity oils capable of being measured if pre-heated to 40-55 *C. Engine oils can be measured for water content and oil life but not ISO codes as laser particle counters do not work on opaque fluids. Filtertechnik have over 15 years of experience in the supply, installation and manufacture of laser particle counting enabled equipment. Our particle monitors are accurate to within +/-0.5 of an ISO code with a repeatability of +/-0.1%. Reporting in ISO, SAE and NAS classes as well as giving the particle quantity counts in the 4, 6, 14 and 21 micron sizes.

The built in Tan Delta Full Spectrum Holistic oil condition sensor monitors the overall condition of the oil giving you unparalleled sensitivity, accuracy and precision, this enables the oil’s remaining useful life to be calculated and displayed. The sensor will work with virtually any oil and the app has a built-in database of over 500 common industrial oils. Filtertechnik partnered with Tan Delta as their sensor is the market leader, it’s proven over many years of operation and is over 60 times more sensitive to oil degradation than any other dielectric type measuring sensor. For oils not on the database Filtertechnik have included a one-time self calibration routine. Virgin oil is taken through a heat cycle to build a profile for the oil, this profile can then be used to determine the remaining life of used oil of the same type. All equipment to take and test samples as well as heat oil is included in the kit. Particle Pal Life gives engineers unparalleled live information as to the state of their oil allowing them to make informed choices regarding their plant and equipment. 0115 9003 600



REDUCE WASTE AND FUTURE-PROOF PRODUCTION WITH AUTOMATIC PRODUCT RECOVERY It seems that everybody is talking about Industry 4.0. Whether you are reading a magazine, visiting a trade show or talking to business consultants, it doesn’t take long for the latest manufacturing buzzwords of ‘Industry 4.0’, ‘fourth industrial revolution’, or ‘internet of things’ to be mentioned. All three terms refer to the shift in industry towards autonomous production systems using not just pre-programmed machinery and robots, but machines which are controlled and monitored by computer-based algorithms, often using the internet to link controls and systems in different locations, sometimes known as ‘cyber-physical systems.’ While there is a lot of hype around Industry 4.0, there is no doubt that the general direction of travel in manufacturing is for the use of more autonomous systems. This trend also presents a fantastic opportunity for businesses to tackle key challenges, such as increasing energy efficiency, improving working conditions, or minimising and preventing waste. For example, installing a system which automatically diverts residual product when it no longer meets specification can significantly reduce waste and improve cleaning processes.

The scale of residual food waste When processing various, often viscous, food products a certain amount adheres to the inside surfaces of machinery and pipework. Some product may also be left behind upon completion of each production run. The scale of this problem is huge, with a 2010 European study suggesting that 4.1 million tonnes of food is lost during processing each year in the UK1, costing hundreds of thousands of pounds annually.


PECM Issue 33

A combination of good design – to minimise the amount of product that remains behind or adheres to the surface – and cleaning systems can be used to overcome the issue. The three main techniques – physical ‘pigging systems’, waterbased flushing, and forcing clean air through the system – all remove residual product as part of cleaningin-place (CIP) procedures. Depending on the range of products handled and product complexity this may need to be carried out several times a day between production batches.

Regaining control While all three of these recovery techniques have the ability to salvage residual product, inevitably, a certain amount is still lost as waste. However, by using inline monitoring equipment linked to a system designed to allow product which meets the specified parameters to be reworked, the amount of valuable product recovered from equipment such as pasteurisers and sterilisers can be maximised. This technique works by using an inline instrument to measures changes in the physical or chemical properties of the product, such as concentration. This information is passed to a controller which determines whether to ‘keep’ or ‘discard’ that material based on predetermined quality parameters. This concept of feedback control is not new in automation. Every HRS pasteuriser or steriliser already has a temperature transmitter and a three-way valve installed after the holding tube. If for any reason the pasteurisation or sterilisation temperature (set point) is not maintained through the holding tube, the temperature transmitter sends a signal to the valve to return the product to the holding tank.

This same principle is now being applied to the HRS Universal Product Recovery System. Rather than just measuring temperature, any suitable physical or chemical property can be continually monitored, such as Brix, pH, viscosity or density. The choice of which parameter is used depends on the nature of the product and the sensors that are available.

Recovery in practice A line producing fruit juice may have a typical sugar level of 12 Brix. The concentration of the juice leaving the pasteuriser is monitored using a Brix meter, and any juice which falls below this level is diverted to waste. The line employs water flushing as part of its CIP systems. Traditionally, because it could not accurately be determined where the mixing zone between residual product and flushing water began, anything passing through the pasteuriser during this cleaning phase would have been discarded, including any perfectly good product left in the pasteuriser at the end of the production cycle. However, by monitoring the product concentration from the beginning of the flushing cycle, it is possible to send juice with a Brix level of 12 or higher to the next phase of production (such as packing), and only discard material which falls below this set parameter. Another example involves a manufacturer of BBQ sauce. Assuming the company makes a profit of 40 pence per litre of sauce, even if 200 litres are lost per production line during cleaning cycles each day, that equates to a loss of £80 a day or £24,000 a year (assuming 300 days production).

If the company has four lines then it is losing almost £100,000 worth of profit, not to mention the creation of around 68 tonnes of waste each year.

Benefitting pocket and planet As well as increasing the amount of product which can be sold, reducing the amount of waste generated decreases disposal costs such as storage, transport and treatment. Alongside these financial benefits, the environmental footprint of the production line will also be improved, with more end product being obtained for the same effort – effectively lowering CO2e emissions per unit produced. Furthermore, cutting down the amount of product mixed in with the flushing or cleaning water means that the resulting waste stream is cleaner and will require less processing, further reducing financial and environmental costs. As all HRS pasteurisers and sterilisers already include a three-way valve to allow for the diversion of out-of-specification product, the only real additional expense are the monitoring and control systems. With potential cost savings running into hundreds of thousands of pounds, such systems rapidly repay any additional capital expense. With manufacturers’ focus on Industry 4.0 now prompting them to reassess the efficiency of all their processes, it’s easy to see why Product Recovery Systems are increasingly being specified alongside both new and existing sterilisation and pasteurisation systems.

About HRS Heat Exchangers Headquartered in the UK, HRS Heat Exchangers Ltd operates at the forefront of thermal technology, offering innovative and effective heat transfer solutions worldwide, across a diverse range of industries. With over 35 years’ experience, we specialise in the design and manufacture of an extensive range of tubular, corrugated and scraped surface heat exchangers. All our products comply with the European PED. HRS has a network of offices throughout the world: Spain, USA, Malaysia, Australia and India; with manufacturing plants in the UK, India and Spain.

Issue 33 PECM





Investment in new staff is very important for the continued success of a company. It is essential to find the most suitable prospects to train and set on the road to a career in engineering. Each year, Sulzer takes on a number of carefully selected interns to experience the day-to-day processes of repairing turbomachinery. As one of the world’s leading providers of maintenance and repair solutions, Sulzer is keen to maintain its excellent knowledge base and prepare talented engineering students for the transition into their professional lives. The company’s internship program is a demanding process where the interns get first-hand experience in what it takes to repair and service rotating equipment. Jennifer Gaines, Mechanical Design Engineer at Sulzer, explains: “The program runs for 12-weeks during the summer and involves working closely with shop


PECM Issue 33

mechanics, machinists and technicians. Once they have the basics mastered, the interns are given an engineering project that is based on the skills they have acquired in the shop.” Prospective interns can expect to learn valuable skills and processes involved in the repair of turbines, compressors, motors, generators and pumps, while Sulzer has the opportunity to discover promising new engineers that can become full-time employees. The Sulzer summer intern program will be running on a regular basis, offering students the chance to develop commercial experience within an engineering environment. Sulzer will be visiting universities to promote the program; however, if you’d like to learn more about this opportunity, please get in touch with Sulzer to find out how to apply.

About Sulzer: Sulzer is the leading worldwide, independent service provider for the repair and maintenance of rotating machines including turbomachinery, pumps and electro-mechanical equipment. With a global network of over 180 technically advanced manufacturing and test facilities, Sulzer offers a collaborative advantage that delivers high-quality, cost-effective, customized and turnkey solutions, providing its customers with the peace of mind to focus on their core operations.Sulzer Rotating Equipment Services, a division of Sulzer, can accommodate all brands of rotating equipment including turbines, compressors, generators, motors and pumps. With an enviable track record, dedicated teams of on-site engineers provide best-in-class solutions to ensure that the most effective service is delivered.


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Issue 33 PECM




MULTIPLE FANS IN PARALLEL: THE ADVANTAGES OVER CONVENTIONAL TECHNOLOGY IN VENTILATION SYSTEMS In many cases, it is advantageous to use multiple fans running in parallel when compared to a large single fan in a ventilation system. Each key benefit for both retrofit and new installations is discussed below. Efficiency Typically 40% of a commercial buildings energy use comes from heating, ventilating and cooling with 50% of the HVAC energy consumption coming from fans. Given the increasing cause for environmental concern, designers should look to select EC plug fans which will not only provide the necessary reliability, but also provide optimum efficiency and environmental benefits. Savings as a result of moving from AC to EC occur from both improved motor efficiency and optimising system design. There is potential to achieve greater efficiency when the system’s operating range includes multiple plug fans running closer to their peak efficiencies, instead of one large fan controlled over a wide operating range. Redundancy Continuous and consistent airflow is essential to virtually every facility. Running fans in parallel allows for redundancy which is designed to improve reliability and consistency. For example, if one fan fails within the ECFanGrid (multiple fan wall from Axair Fans), only that portion of the airflow is lost, unlike single fan systems where the entire air handler goes offline. Moreover, the loss of airflow from one plug fan can be offset by increasing the speed of the remaining fans; this can be achieved automatically in conjunction with the building’s management system. Flexibility The number of plug fans in each ECFanGrid system can vary according to the airflow requirements. For example, in a wall of 9 fans in a 3×3 configuration where only 7 fans may be required for normal operations to deliver the designed duty, the 8th and 9th space can be blanked off with a plate. If the demands on the AHU increase through building expansion for example,


PECM Issue 33

the blanking plates can be removed and 1 or 2 fans added to the grid to meet the new requirements. Ease of installation ECFanGrids are ideally suited for retrofit AHU projects, particularly where a single large radial fan is being replaced. It is often the case that buildings have expanded around an AHU over its years of operation. This can make the extraction of the old fan problematic but the install of the new fan impossible without minor works to the fabric of the building. Plug fans can be walked through standard pedestrian doorways by no more than two operatives: a significant factor in maintaining a tight replacement schedule, reducing costs and downtime. Ease of maintenance Unlike a traditional belt drive unit which covers a large floor space, the ECFanGrid is completely free of the floor. This means that maintaining the hygiene of the AHU is quicker, simpler and more effective. No dust is released into the supply air as there

are no belt drives to degenerate over time. Furthermore, component failure is quickly dealt with due to the modular nature of the ECFanGrid. For example, a single fan module could be replaced and the AHU back online within an hour of being shut down. Noise Attenuation Case studies show that there is the potential to significantly lower noise when using an ECFanGrid. There are two major advantages to attenuate noise. First, the noise spectrum of smaller impellers contains higher frequencies, thus the wave lengths are shorter, allowing for the use of shorter attenuators. Second, the required length of the fan section in a typical air handling unit using a single large radial fan can be reduced dramatically, in some cases up to 50%. For more information on Axair’s ECFanGrid, please visit, call 01782 349430 or email

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Sulzer Turbo Services Houston Inc ,’s annual Hack Attack golf tournament, which is held at the Golf Club of Houston, has raised USD 80’000 this year for the local Today’s Harbor for Children charity. This year’s event also celebrates the charity’s 70th anniversary. The tournament is held in April, which is also Child Abuse Prevention month. Taking place at the home of the Shell Houston Open, the charity golf tournament organized by Sulzer Turbo Services Houston Inc. helps raise money to provide residential care for children that have been abused, abandoned or neglected in the Greater Houston Metropolitan Area. With only 144 players invited to take part, each one raises considerable sponsorship for the very worthwhile cause. The day got off to an early start with breakfast at 6:30 a.m. and a shotgun start at 8 a.m. for the scramble format that would ensure all the players completed their rounds together. Aside from the team matches, there were several other competitions including a hole-in-one contest to win USD 10,000 cash and prizes


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for the longest putt, the longest drive and the shot closest to the pin. Over the years there have been some notable participants to the Hack Attack, such as Tim Drury and other long-standing customers of Sulzer Turbo Services Houston Inc. In addition, the continued support of some of its suppliers, such as Fred Gorman of Gorman Uniforms and David Bailey from Bailey Steel is greatly appreciated. Darayus Pardivala, President Americas, Rotating Equipment Services, commented: “Sulzer Turbo Services Houston Inc. has a long tradition of supporting the local community and this event has been an

incredible success that enables us to help a very important cause. All of the players have had a great day and managed to raise a fantastic amount of money for some of the most vulnerable young people in our area.” Don Sweat, President & CEO for Today’s Harbor for Children, concludes: “As the beneficiary of the event proceeds, we are able to continue guiding our children through to their next destination. Thanks to Sulzer’s continued support, now and moving forward, our mission to provide stability for youth in crisis is further ensured. We are honored to be a part of this extraordinary event.”

About Sulzer: Sulzer is the leading worldwide, independent service provider for the repair and maintenance of rotating machines including turbomachinery, pumps and electromechanical equipment. With a global network of over 180 technically advanced manufacturing and test facilities, Sulzer offers a collaborative advantage that delivers high-quality, cost-effective, customized and turnkey solutions, providing its customers with the peace of mind to focus on their core operations.




Did you know that 3D printers could save you over €80,000 within a 12 month period in a factory making over 15 million electronic parts per year? We’ve learned that implementing our solutions at the Bosch Mondeville plant in France and working with other key players within other industries ranging from automotive to aerospace. In most cases, the investment in Zortrax 3D printers returned tenfold within a few weeks and as you should know, it takes the right tools and the right people to achieve such a feat. After talking to industry leaders and plant managers we have identified many key issues that could be solved with 3D printing. Plastic grippers, plugs, jigs, and fixtures are needed in vast quantities to keep the production line going. At Bosch Mondeville plant they had grippers for robotic arms costing €400, with 3D printing this only cost them €1.


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Custom made tools can be designed, 3D printed on the spot within hours and the Zortrax M200 Plus 3D wireless 3D printer has been constructed to deal with those issues. The Zortrax M200 Plus with dedicated Z-SUITE software ticks all those boxes. Making things work at production level is not only about technology…… it’s about people. Engineers at large factories usually have extensive experience with CNC machining and 3D printing is often not what they’re used to. That’s why we provide personalized training, advice, and support service. Our teams begin with visiting the plant to identify key challenges and offer ideas on how to overcome them. In a typical scenario, it takes under a month to set up a 3D printing farm and train the staff to operate it efficiently. Once that’s done, Zortrax M200 Plus 3D printers will start doing their job and saving money.

To offer viable solutions we had to define what makes a fused deposition modeling (FDM) 3D printer work in industrial applications. •

First, it had to keep the costs low. FDM is still the most cost-efficient 3D printing technology which comes in handy given the parts in large factories which are needed in large quantities.

Second, it had to be reliable as it’s easy to build a machine that can print a near perfect part once, twice or even a few times. Being able to make it print with consistent quality for 24 hours a day, 7 days a week for half a year with almost no maintenance is an entirely different story.

Third, the printer had to be easy to use for untrained staff.

Fourth, we had to come up with a way to efficiently manage tens or hundreds of machines.

Krzysztof Cichocki +48 735 206 727


Flotronic Pumps’ original 10” ‘H’ Series pump was designed to meet the exacting hygiene standards of 3-A Sanitary Standards, Inc (3-A SSI) and to be used in processes where hygiene is a priority. The range has been expanded to encompass 7” and 12” versions, offering both low and high flow rate pumps to meet the needs of the hygienic product transfer market, and both pumps are 3-A SSI

Accredited. The ‘H’ Style pumps are designed so they can be thoroughly Cleaned in Place (CIP) benefitting from the innovative, easy-maintenance, ‘ONE-NUT’ design for which Flotronic is renowned, allowing pump maintenance in a matter of minutes. Pipework connection sizes now available from 1” – 3” allowing greater versatility.




CHALLENGE NON-RETURN TO SEWER ALLOWANCES! The WasteWater Meter WWM™ from Micronics is a cost effective and reliable solution for measuring the flow in waste water pipes, to challenge non-return to sewer allowances and comply with Effluent discharge licence requirements. A unique British product that provides accurate waste water metering through non-intrusive microwave technology and measures flow in pipes containing clean or dirty water on gravity systems. No V Notch Weir required! The meter has a local volumetric display and a R.A.S. (Remote Access Service) logger, which provides real-time monitoring via a mobile data network and a comprehensive web dashboard. And blocked or partially blocked pipe alarms are also available. By measuring the input water supply and then the outflow with the WWM™ end-users can see a true reflection of the water used in their particular process, including a real outflow value for accurate billing. The WWM™ is CE Approved with MCERTS and suitable for a wide range of applications including: Waste water outflow, Effluent discharge licence compliance and Blue & Grey water measurement.

Litre Meter now distribute the Lake Monitors range of VA meters for a variety of applications including bidirectional flow, high temperature and high pressure. The Basic unit is rated to 116°C and 240 bar in brass. High

temperature versions rated to 315°C and high pressure versions to 410 bar are in stainless steel. There are versions for pneumatics, hydraulic test analysis and phosphate ester measurement, too. Call today.

Issue For further information call33usPECM on 31

GEOFF BAKER BECOMES INSTITUTION’S NEW PRESIDENT Geoff Baker MSc CEng FIMechE has assumed office as the 133rd President of the Institution of Mechanical Engineers and has set out an exciting vision for the future of the Institution.

Geoff said of his appointment: “In the Year of Engineering, I am delighted to have been elected by the membership to be President. I intend to engage with them and wider stakeholders to ensure we have an Institution that is relevant and fit for purpose in the 21st century. “Our engineering profession is in the process of radical change. Change that is challenging, not just people’s perspective on our profession but also the way it has operated for the past 170 years. Society will call upon engineers to solve the challenges the world is now facing: how we will live with an exponentially increasing population, how we will feed ourselves, and how we will deal with the

challenges of climate change. As President, I hope to create an environment where talent can come together to address the multidimensional issues which society faces.” Geoff Baker is an entrepreneur and engineer with a distinguished international career. Geoff has global business experience and has established business operations in Europe, America, the Middle East, Malaysia and Australia. He co-founded two successful engineering companies, the ATL Group, a leading technical services company in the industrial, defence, oil and gas markets which was sold to Bureau Veritas, and Plant Asset Management Ltd, which was subsequently acquired by FTSE oil services company, Petrofac.

NEWS He started his career serving a five-year Mechanical Engineering Apprenticeship with the British Aircraft Corporation and graduated with a Master’s Degree in Mechanical Engineering. Geoff has been an active member of the Institution since his early career. In addition to his personal business interests, Geoff works hard to advance and promote the engineering profession through his three major passions: the encouragement of innovation and entrepreneurship in engineering, inspiring young people into engineering, and pioneering change in the engineering profession, which he believes is required to make it more relevant and responsive to needs of society.

Following both acquisitions, Geoff held senior executive positions within these organisations.

COMPETENCE OF UK ELECTRICIANS RECOGNISED BY NEW NATIONAL STANDARD A first-of-its-kind national standard that marks the competency of individual electricians in the UK has been launched by the Institution of Engineering and Technology (IET) in collaboration with the Engineering Council.

“We believe that safety critical, electrotechnical work, is largely hidden within the fabric of buildings and it is, therefore, down to the individual electrician to be accountable for the work they do, both in design, installation and maintenance.”

The national Recognised Electrician EngTech Standard is for electricians undertaking electrical installation, maintenance and remedial works in buildings and dwellings and is awarded via competence based peer assessment.

“This recognised standard will not only provide the industry with a competency benchmark, but will give companies reassurance that they are recruiting a highly skilled workforce.

Such an assessment will provide a national benchmark of competence for electricians working in safety critical roles and means companies will be able to confidently recruit and retain highly qualified and professionally registered electrical workers. Michelle Richmond, IET Director of Membership & Professional Development, said: “The IET has, for some time, been concerned that electricians working on both basic electrical installations and complex high rise buildings should have the appropriate demonstrable qualifications and competence.


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Other benefits would see a reduction in recalled work and associated unplanned costs, providing financial efficiencies too.” The new national standard supports the final Hackitt report (published 17.05.18)* which proposes improvements regarding the competence of people who are involved in the design, construction, refurbishment, occupation and maintenance of buildings. It highlights whilst there are many instances of competent people, there is no consistent way to assess or verify their competence which allows individuals to practice with questionable qualifications or without a


requirement for competence assessment. Developed through an IET led national working group of sector stakeholders, the new national standard provides the foundation for the recently awarded national IET Certification Mark RPE (Registered Professional Electrician). Electricians achieving RPE will meet the highest ethical standards, operate under a professional code of conduct and commit to continuous professional development and audit. A similar approach of developing recognised standards could be applied across different disciplines in order to gain similar recognition for competency and compliance to the highest level of industry and safety standards. For more information, visit and/or email:

RMIG is the world's largest manufacturer and supplier of perforated metal and its related products. We know our customers’ requirements for price and quality and meet their demands with uncompromising service. Not only do we offer standard and bespoke perforated metal sheets, we are able to offer you a range of secondary operations as detailed below. Complete solutions With a continued investment in the latest equipment and a network of professional partners we are able to produce prime quality products and solutions – from a simple perforated sheet to the fully formed and coated custom made part.

Cutting We can cut and shape perforated sheet to meet the needs of your final application. Levelling For some applications a high degree of flatness is required, we have processes in place to ensure our perforated coils and sheets meet with your most demanding requirements. Rolling and forming We can roll, bend and form perforated sheets to match your design. Aesthetic finishes and protective coating We can offer powder coating and hot dip galvanizing solutions to meet your specifications. For more information please contact us Tel: 01925 839610

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The performance of existing plant and machinery can sometimes be markedly improved by the simplest of modifications, such as retrofitting a better quality transmission chain. Greg Sharp of Tsubaki UK expands on the concept and looks at some real-world examples where productivity and profitability gains were achieved. It is easy to take transmission and conveyor chain for granted. Often viewed as a commodity product, it's easy to overlook the demands and stresses placed on each link during operation. The effects of impacts, misalignment, harsh conditions or poor maintenance can quickly lead to wear or damage, which can result in lost production hours. This creates an interesting opportunity: why not consider using a high quality or specialist replacement chain that will lead to better overall machine performance?


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An interesting point to bear in mind here is that when the machine was originally built, whether by an in- house team or by an external OEM, there will have been a budget to meet. It is entirely possible that the chain fitted at that time was procured on price rather than optimal suitability for the job in hand. Replacement of that chain with one better suited to the duty could therefore prove extremely beneficial. A replacement chain could be better from a number of different stand points. For instance, a lube free chain could provide a fit and forget alternative to standard, externally lubricated chain. While this may seem like a minor saving, across even a modest sized plant you could be saving several man hours a week, plus the constant cost of buying in more lubricant. Lube free chain also significantly reduces the risk of a catastrophic failure caused by accidentally missing out a lube point or two or by using the wrong oil.

Due to environmental challenges many chains have to be replaced regularly. In such instances it is tempting to specify budget chains in order to reduce costs. However, an alternative is to actively seek out a better quality chain that would last longer. It is not unusual to double or quadruple chain life by upgrading to a product that is optimally suited to the work load and environmental conditions, and some fairly simple calculations will allow you to quantify the overall savings. Another possibility for achieving cost savings with a retro-fit chain is where attachments are fitted to the new chain so that it becomes a bespoke component ideally suit to the job in question. In this case, it is difficult to generalise as each application will be unique, so let us look at the following example.

Body parts For a German machine builder for automotive assembly line, one of its most popular products was a conveyor system for vehicle body panels and other parts. Originally the manufacturer developed its conveyor design using a standard conveyor chain. However, it became apparent that due to the heavy loads and long duty hours the lifetime of the original chain was short. Once installed there was a need to regularly re-lubricate the chain, a process that represented a ‘hidden but real’ cost. In use the chains soon became stiff and difficult to articulate as contamination built up on the links, leading to a maximum working life of 12 months. Also, many of the top plates were coming loose due the poor riveting, which often led to unexpected chain breakages and production stoppages. The machine builder wanted to improve on its machine design and so invited experts from Tsubaki to conduct a review and suggest possible solutions. Several ideas were discussed; the one chosen was to switch from the original commodity chain to Tsubaki’s maintenance free Lambda chain, with every second link replaced by a special top plate which eliminates the need for lubrication. The result of this was that contamination of the new chain was minimised preventing the previous stiffening so that free articulation was maintained in the long term. Tsubaki engineers also offered special high tensile screws and high strength adhesive to prevent the screws from coming loose. These changes were implemented, producing advantages of no breakages, longer life and reduced maintenance cost.

Paper mill A similar problem was evident at a paper mill where, although the loads were far lighter, tiny pieces of tissue paper were quickly compromising the chain lubricant in a tissue log saw accumulator. Tissue paper is made in a large continuous web that is rolled up into logs as it is produced. These logs are then cut to length to produce rolls of kitchen and toilet paper. The cutting process creates what is effectively sawdust, which flies around and can settle on chain to create a sticky mess by soaking up oil. This sawdust debris caused the chain to become stiff, which led to the logs being tipped out of alignment and the accumulator blocking up. The accumulator’s maker switched to Tsubaki Lambda chain and saw an immediate improvement. The manufacturer also adopted Tsubaki’s match-and-tag service in which chains are precision measured and paired up so that when they are installed in parallel on a machine they operate in perfect synchronicity. For this application the resultant improvements meant that there is no longer any sideways drag on the tissue logs to pull them out of alignment.

The benefits for the paper mill included longer chain life, lower maintenance, less product contamination, fewer mis-cuts and higher overall productivity.

Best thing since sliced bread Bakeries need their bread lines to run like clockwork so that they can reliably deliver fresh loaves every day. One bakery had built a transfer conveyor to take loaves from the continuous ovens to the packaging and dispatch area as efficiently as possible. This was based on a design using five parallel strands of 0.5in pitch roller chain. To maintain hygiene standard all plastic chain was specified. Unfortunately, the OE chain proved unsuitable in that it became brittle due to the hot environment and regular scrubbing of the dry cleaning process; this lead to regular breakages. Further exacerbating the issues, each strand of chain stretched at different rates, which caused the loaves to move erratically towards the sides of the conveyor, from where they could fall onto the floor.

MRO Expertise Increases Productivity Each of the cases above demonstrate the important role that MRO professionals can play in the profitability and success of manufacturing operations. Beyond keeping a plant operational, it’s possible to engage with engineering expertise to identify areas for improvement and make a tangible improvement to the bottom line. Transmission chain will always eventually wear and need replacing. This presents maintenance engineers with the opportunity to investigate alternative solutions to the original equipment. Working with a specialist manufacturer such as Tsubaki makes it possible to tap in to over 100 years of expertise. For almost every industrial application it is possible to increase chain life, reduce maintenance costs or improve efficiency in operation.

Having identified the problem, the bakeries maintenance engineers approached Tsubaki to see if it could suggest a replacement solution. Tsubaki offered a solution by replacing the original chain with one based on solid extruded plastic inner links coupled with stainless steel bearing pins and outer plates. This is stronger than an all-plastic chain, lube-free and very hygienic so suitable for food industry applications. Since the swap the bakery has reported no faults and no unscheduled stoppages.

About Tsubaki Established in 1917, Tsubakimoto Chain Company is the world’s premier manufacturer of power transmission products with strong market positions in premium quality industrial drive & conveyor chains and associated power transmission components such as cam clutches, reducers & linear actuators. With a turnover exceeding $1,5 Billion US Dollars & 6,500 employees, the Tsubaki group includes 33 manufacturing locations and 77 group companies worldwide. Our production and sales networks are now more developed than ever.

Amazon Filters Helps Improve Major Pharmaceutical Off-Gas Filtration System

New BOGE LPT150 oil free compressor cuts cost of ownership by 30%

Amazon Filters reports on the supply of significant quantities of SupaPore TPB PTFE membrane filters to a major pharmaceutical company for off-gas filtration of their largescale fermenters.

BOGE Compressors has launched an innovative new oil-free system, the LPT150, that cuts total cost of ownership by up to 30%.

In the preparation of vaccines and cultivation of pathogenic microorganisms, the chance of hazardous microorganisms escaping from the fermenter into the environment must be prevented. For further information please visit To discuss how to improve your fermenter off-gas filtration please contact Amazon Filters on +44-1276-670600 /

Putting air pollution on the map The nature of air pollution may have changed in recent decades, but it still has a significant impact on health and wellbeing across the world, especially for those with underlying respiratory conditions. To combat this global health menace, many countries’ planning processes require calculations for the dispersal of air pollution, when developing new buildings and infrastructure.

At the heart of the new compressor is a compact permanent magnet motor, with a central rotor suspended on self-stabilising air foil bearings, with precision balanced titanium impellors mounted at each end of the rotor.

Mapping software is used to bridge the gap between the science needed to understand it and engineering being planned to mitigate it. Understanding this can help people identify and control air pollution.

This, arrangement allows air to be drawn in via an intake funnel and specially-designed spiral casing and thus to be boosted in stages to reach operating pressures quickly and efficiently

Advanced Gas Detection Made Simple Here at IGD we have launched the new TOC625 MICRO, a multi-channel gas detection system, that can be configured with up to 6 detectors and 2 relay options. With 1 click automatic setup, deploying a gas detection system has never been easier. The system is designed with advanced automatic set-up features. Once installed, all that is required to set-up the system is one click of a button. Addressable gas detection systems allow you to quickly deploy an effective safety solution.

The controller features auto-setup functions which enables auto-configuration of the gas detection system alarm levels, gas types and ranges. The systems allow for the use of pre-calibrated detectors. Only a single cable is required to interconnect the controller, detectors and relay modules. Addressable gas detection systems of this type typically save up to 70% on installation costs. Furthermore the 625 MICRO can be easily integrated into any fire system or BMS system allowing for a fast, flexible and complete safety system.

There is also a pre-wired version of the system using plug and socketed cables (TOC-625MCP). This version allows for installation by people with no gas detection experience. Cables are available in 1m, 3m and 10m lengths which can be interconnected to make specific length cable runs. 625 MICRO is ideal for a wide variety of applications that require a small gas detection system, these can include: • • • • • • • •

Boiler plant rooms Breweries: Micro breweries Pub Cellars Small laboratories Commercial Kitchens Schools: including: craft rooms, laboratory rooms, boiler rooms and class rooms for CO2 monitoring. Underground carparks

Introductory Video link:


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Register your interest to visit the UK’s largest engineering event, giving you access to: � 600+ exhibiting suppliers and partners � 200+ Continuing Professional Development certified presentations and case studies from OEMs, industry experts and government � Innovative and exciting feature exhibits showing the latest technologies in action � Enabling Innovation zone for SMEs and start-ups to present new inventions and idea

Register your interest to attend at: #AEUK18



STREAMLINE: AUDI E-TRON PROTOTYPE WITH DECISIVE AERODYNAMICS The scenario: endurance tests in the wind tunnel In front of the low-noise rotor measuring around five meters (16.4 ft) in diameter, the Audi e-tron prototype stares into the eye of the hurricane. On the aeroacoustics test rig in the Wind Tunnel Center in Ingolstadt, the world’s quietest vehicle wind tunnel, the Audi engineers optimize drag and noise under extreme conditions. Both are crucial for a car’s efficiency and comfort. With an output of 2.6 megawatts, the fan produces speeds of up to 300 km/h (186.4 mph). The Audi e-tron prototype was put through over 1,000 hours of testing here. The result: a drag coefficient of 0.28. Customers benefit directly from this low figure as drag contributes decisively to the high range of more than 400 kilometers (248.5 mi) in the WLTP cycle. A hundredth of the drag coefficient figure represents a range of around five kilometers (3.1 mi) driving under everyday conditions.


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Drag: essential on long journeys On long journeys where the Audi e-tron prototype is perfectly at home, the drag constitutes the key driving resistance – far more important than the rolling resistance and inertia. The energy is lost which the car needs to overcome this resistance. That is why good aerodynamics are so important. In urban traffic, however, other factors come into play. Here an electric car can recover a large part of the used energy when braking, thereby reducing the importance of its mass. To achieve the drag coefficient of 0.28, the Audi engineers developed a wide range of aerodynamics measures in all body areas. Some of these technical solutions are evident at first glance, while others fulfill their purpose hidden away from sight. Thanks to these solutions, the drag coefficient for the Audi e-tron prototype is almost 0.07 less than for a comparable, conventionally powered vehicle. With a typical usage profile this set-up increases the range by around 35 kilometers (21.7 mi) per battery charge in the WLTP cycle.

Smart solutions: virtual exterior mirrors and dimples on the underbody The optional virtual exterior mirrors will be making their world premiere in the volumeproduction version of the Audi e-tron prototype. They are much narrower than the standard mirrors: They reduce the vehicle width by 15 centimeters (5.9 in) and, thanks to their new shape, not only reduce drag, but also noticeably cut the nonetheless low wind noise. Each of their flat supports integrates a small camera. The captured images appear on OLED displays in the transition between the instrument panel and door. The virtual exterior mirrors can be adapted for various driving situations, thus potentially improving safety. Three views are available in the MMI system – for highway driving, turning and parking. Another important factor is the standard adaptive air suspension – a pneumatic suspension with adjustable damping. At speeds above 120 km/h (74.6 mph), it lowers the body by up to 26 millimeters (1.0 in) below the normal position, thus reducing the drag.

The underbody of the all-electric SUV is fully enclosed; the front and rear area are fully paneled. Underneath the passenger cell, an aluminum plate protects the high-voltage battery against damage from below, such as stone chipping or curbs. Its bolting points come with bowl-shaped indentations, similar to the dimples on a golf ball. They make the air flow much better than a totally flat surface. Additional information about the Audi e-tron prototype is available at

Electric car with sophisticated aerodynamics concept: drag coefficient of 0.28

Important factor particularly on long journeys: drag

For the first time in a volume-production car: virtual exterior mirrors as a high-end option

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DISCRETE MANUFACTURERS OF ALL SIZES SHARE A DATA PROBLEM: HOW TO MAXIMIZE VALUE FROM ALL THE INFORMATION THAT IS AVAILABLE ABOUT PRODUCTS AND SERVICES? Actify is passionate about using business intelligence to make manufacturing companies smarter by harnessing the product data trapped in all their data sources. At Actify we provide a set of business solutions designed to support the creation, management, dissemination and collaborative use of product data (i.e. product definition information including BOM structures, CAD files, specifications, requirements, manufacturing instructions, etc.).

Information is recognized as a business asset that creates real value. The magnitude of information is continuing to increase driven by the proliferation of data from the internet of things (IoT).

Disruptive technologies like Actify Product Data Intelligence can help liberate your enterprise data and increase results without the typical costs! Product Data Intelligence facilitates data visibility and data usability.

Sharing product data in the enterprise in meaningful ways that unlock insight and support collaboration, efficiencies, and cost reduction is critical to expanding data’s worth. The more that data is shared and reused, the more value is extracted from it and the higher the benefits are for companies, such as being faster, better, and cheaper at producing products. However, there are many barriers when it comes to sharing data because companies have created siloed data sources that are difficult to find and access.

Having the maximum amount of information available to contextualize the current state of play allows managers to make the best decisions and improve business outcomes.

Today’s business problems are not about creating more data or buying additional expensive and complex technology, but rather accessing the existing business data and gaining insight. Over the years manufacturing companies have spent a fortune on expensive CAD, PDM, PLM and ERP systems without ever gaining the promised results. Just imagine if you could release the business value that is trapped in these applications and other key data sources like spreadsheets.


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The associated benefits of Product Data Intelligence are illustrated above as a demonstration of value. Do not hesitate to contact us for more information and for a personalized demonstration of value for your organization. Actify define their technology as Product Data Intelligence, because today’s Business Intelligence solutions do not understand product definition information or handle the types of files that are synonymous with engineering and manufacturing organizations. Discrete manufacturers’ data is unique, because the information assets include 3D models and 2D drawings where information is hidden within CAD files (dimensions, eBOM, PMI, GD&T, etc.)

Many of today’s manufacturing companies store their data in line-ofbusiness systems like PLM, ERP and Excel spreadsheets, but not everyone has access to these systems, and the user interface may be cumbersome for the casual user. Actify solves this challenge by enabling crossdepartment collaboration, data management and quick access to extended product data that can help make critical business decisions faster. We believe that software tools can provide tremendous benefits especially for manufacturing companies, through the intelligent use of their available data and through automating mundane processes. Contact Actify for more information. Visit: Email:



OPTIMAS SETS THE COMPONENT SUPPLY STANDARD FOR TIER 1 AUTOMOTIVE ASSEMBLY SUPPLIER Simplifying the fastener requirements of a multi-billion-dollar automotive assembly supplier demands a consistency of approach - a methodology that Optimas refers to as a global component standard. Since 2009, Optimas has been applying this standard to the activities of a global manufacturer of interiors, seating and emissions solutions to some of the world’s most prestigious car manufacturers. With the cooperation between the two businesses providing distinct advantages in the manufacturer’s European interiors division, the standard is now set to expand globally. The customer initially enlisted the help of Optimas to help generate efficiency gains and cost savings within its fastener supply network, which with operations in 35 countries, presented a sizable challenge. Optimas gathers a vast wealth of experience supporting Tier 1 automotive suppliers and OEM manufacturers, so the customer was confident that Optimas had the expertise necessary to help streamline component selection in its interiors division. Engineers from both businesses began a series of fastener implementation meetings to define a unified approach to fasteners. Eric Crassous, Development Director and OEMS Global Account Director at Optimas, explains: “The end goal was to standardise the manufacturer’s fastener policy in Europe, so that components and suppliers could be effectively consolidated to simplify component specification and delivery. To this end, our engineers worked with the interiors division to define a catalogue of components - a global standard for fastener selection. We recommended already existing parts within its component portfolio that met engineering requirements, while also removing obsolete part numbers from the manufacturer’s fastener usage. The end result was a defined list of 17 standard part numbers, which met 82% of fastener requirements for the division.” The global standard fastener catalogue offered a number of advantages. First, it consolidated the vast majority of fastener supply activities within Optimas, providing the Tier 1 supplier with one point of contact for all fastener requirements. By maximising order volume through limiting component diversity, Optimas was also able to provide parts at a more competitive cost point


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than the previous supply framework. Furthermore, due to Optimas’ highly efficient global network and localised fastener warehouses, lead times on fastener orders were also reduced. “By consolidating and simplifying component specification for the customer, we effectively reduced decision time for engineers on the ground,” Eric continues. “Rather than specifying an entirely new component for a certain application – which requires designing it, creating samples and working through sign-off protocol – the customer’s engineers can now simply refer to the catalogue for an existing solution. For the interiors division, this delivered immediate efficiency gains. “For the future, we minimise obsolescence, as fasteners that were used in a previous project can be reapplied throughout the manufacturer’s global operations in new projects or designs. This approach provides maximum usage and increased cost effectiveness.” For the customer as a whole, this conveys a united and integrated approach. A defined fastener catalogue can be an excellent tool in displaying proficiency, as well as uniting the company with regards to approaching these issues. With a point of reference such as this, decision making is streamlined and efficiency boosted, providing the customer with less challenges to overcome and an increased ability to perform. So what of the remaining 18% of fasteners? These non-standard components are not included in the catalogue, but instead of enforcing a one size fits all policy, Optimas adapts to the manufacturer’s specific component requirements in real time. Due to a close relationship between both sets of engineers, the two teams collaborate to originate custom parts to overcome specific

application challenges. A new design outside the global standard can therefore be accommodated for, with Optimas utilising its network of independent test laboratories and supply capacity to deliver these custom components with increased speed. Ultimately, it provides the best of both worlds. Eric concludes: “The proven success of this fastener framework - a combination of global standards and adaptability - has grown a committed relationship between both businesses. Now, together we are starting the journey towards implementing similar fastener solutions in the manufacturer’s seating division, an initiative that has been enabled due to prior success and mutual trust. By actively supporting this Tier 1 automotive supplier’s innovations with quality, simplicity and reliability – we try to overcome the role of a traditional supplier, instead operating to the standard of an integrated fastener partner.

About Optimas Solutions Optimas is a global distributor of fasteners and c-class products. Optimas at its core is a provider of integrated supply chain solutions and engineering support focused on delivering highly engineered fasteners to world-class customers around the world. Optimas has a diverse, global team of approximately 1,600 individuals, over 60 distribution centers, 9 quality labs and 2 manufacturing locations to support the complexities of our customers’ industries, enabling them to achieve their goals and be successful.


Founded in 2000 Digital Echo is the largest capacity bureau service for bespoke, prototype and low volume investment castings in the UK and has developed an excellent reputation as an integral part of the automotive supply chain process. Recent investment in the latest generation of large format ultrahigh definition wax printers has enabled Digital Echo to produce production quality investment castings direct from CAD without the need for any tooling, saving customers time and money in the low volume manufacturing markets plus provide accurate research and development analysis before committing to high volume expenditure. Through Digital Echo’s foundry business development relationship they have become an established supply chain provider in the Automotive & Motorsport sectors, to TS16949 standards, from engineering castings in stainless steel, aluminium and nickel alloys, through to jewellery quality interior and exterior cosmetic components.


This relationship also provides the end customer with a one-stop solution should high volume manufacturing be required – Digital Echo’s unique capacity means that component production can start immediately – while the high volume tooling is being created and then seamlessly migrate over to full manufacture when tooling is complete. As Digital Echo has grown over the past 20 years so have the market sectors that benefit from Digital Echo’s manufacturing process which now include: • • • • • • •

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FULTON’S PURE TECHNOLOGY APPROACH ACHIEVES WORLD-FIRST VERTICAL STEAM BOILER DESIGN WITH HIGHEST EFFICIENCIES AND ULTRA-LOW NOX EMISSIONS The gas-fired VSRT steam boiler emerges from Fulton’s new ‘PURE Technology’ approach, an initiative that’s delivered a world-first design that is durable, longlasting and boasts the highest efficiencies and ultra-low NOx emissions. By adopting a systems-engineering approach and implementing PURE Technology – the result of a clean-slate design approach that combines new people with new skills bringing a new approach to the design and optimisation of heat transfer solutions – Fulton’s VSRT radically challenges the heat transfer and mechanical design principles of traditional steam boilers. It’s also claimed to be the most radical change to vertical steam boiler design since Fulton pioneered the vertical tubeless boiler in 1949. Commenting, Fulton’s Leigh Bryan says: “To meet stringent industry and environmental standards, PURE Technology looks to enhance heat transfer, provide classleading efficiencies, improve steam quality and reduce NOx emissions. Rather than improve existing products to achieve this, we are engineering new solutions that are fit-for-purpose and application.” With 15+ patents pending in three continents, the VSRT attains industry-leading heat transfer rates thanks to a unique

spiral-rib heat exchanger to achieve low stack temperatures by passing flue gases through a fully-water-immersed, spiralwound heat exchanger. This design extends the heat transfer path and dual-direction heat flow, with the spiral annulus designed and optimised to create high heat transfer rates. This improves efficiency and creates a longer-lasting boiler that Fulton believes will beat the competition in every category of durability thanks to virtually zero thermal stress, a thick-walled construction and its vertical tubeless design architecture.

This achieves >10:1 turndown capabilities and industry-leading performance of >82.5% gross thermal efficiency and 99.75% steam quality at 8 bar.

A fully-water-backed pressure vessel is wrapped in high-density insulation to achieve minimal thermal losses and low outer surface temperatures; and the tubeless design has created a compact boiler with minimal footprint.

Maintenance is further improved thanks to a revolutionary air filter where, for contaminated combustion air environments that can reduce boiler uptime, a cyclonic air filter separates debris and damaging particles and eliminates the need for replacement filters.

No refractory also means significantly lower weight to ease installation. The VSRT’s combustion technology achieves ultra-low NOx emissions of <20ppm and features a fully-matched modulating burner and furnace purposely-designed as a single component.

When correctly sized for applications, the exceptionally high turndown will result in savings above-and-beyond those gained from stated efficiencies. With a tubeless design, no internal refractory, industrial control platform and easy access to the pressure vessel, the VSRT is easy to maintain and operate.

The VSRT is currently available with outputs from 160-960 kg/h, complies with MCPD regulations and the City of London Air Quality Strategy; is constructed to BS EN 12953; and CE marked to PED. It comes with a five-year guarantee on the pressure vessel and burner.

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PECM Issue 33

Full steam ahead with help from Riello Riello has donated an RL34 oil burner to the Internal Fire Museum in Cardigan for use in the first of its steam halls. The burner is fitted to a Beel VFB boiler donated by Cochran UK. The Internal Fire Museum was founded in 2003 to cover the history and use of large engines in the 20th Century. The first of the steam halls was opened in April 2018. The Museum’s Paul Evans commented: “The steam hall has seen a fantastic show of help from companies such as Riello and Cochran. Without the generous assistance of these companies the museum would not have been able to complete the project on schedule.” The RL Series of two-stage burners covers a firing range from 154kW to 2700kW. For further information visit

Major hospital acts to ensure continuity of heating in the event of boiler system failure


A major UK hospital has implemented an emergency contingency plan to ensure continuity of heating and hot water to wards, operating theatres and offices in the event of failure of its primary boiler system. The FM company responsible for building services on the large site has contracted Watkins Hire to provide a high efficiency standby boiler system to replace the main boiler in the event of failure, under the hire specialist’s Temperature Control Emergency Planning Services (TCEPS) scheme. Following site surveys to assess the requirement, Watkins proposed installation of a 3000kW MTHW boiler and associated fuel package.

Swindon based combustion equipment manufacturer, G P Burners (CIB) LTD, has appointed Daniel Goulding to the post of Managing Director. He replaces Jim Spearing, who is retiring after nearly 40 years in the post, during which he oversaw the acquisition of the company by Italian manufacturer, CIB Unigas S.p.A. Daniel (33) has a BA in Business Management from the University of Gloucestershire. After graduating, he retrained as a commercial electrical engineer, before joining G P Burners in 2011. During his time with the company, he has acquired a broad range of industry experience in a number of roles, most recently as a commissioning engineer.

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ALLOWING THE UK ROBOTICS INDUSTRY TO EMBRACE OPPORTUNITY Brian Foster, Head of Industry Finance at Siemens Financial Services in the UK, explores the opportunities for the UK’s innovative and growing robotics industry. Businesses and consumers are waking up to the power of robots, as advancements in new generation digitalised technology (also known as Industry 4.0) are helping to transform the robotics industry. Traditionally deployed in the industrial manufacturing process, new robot types such as consumer or personal assistant robots and unmanned aerial vehicles (UAVs) are growing in popularity with many other robot types, such as autonomous vehicles, emerging on the horizon. This popularity is set to grow, and the worldwide robotics market is predicted to reach $237 billion worldwide by 2022, more than seven times its 2016 value of $31 billion. Europe is at the forefront of this growth. Across the EU and from the USA to China, major industrial nations have identified robotics and Artificial Intelligence (AI) as strategic economic and policy priorities. The UK currently trails behind Japan, Germany, the USA and many other nations in the uptake of industrial robots. This is in stark contrast to the strength of the UK’s automotive and aerospace industries. The UK is the second-largest aerospace manufacturer in the world and UK car production reached its highest level in seventeen years in 2016. It is interesting to note that the use of robotics in UK manufacturing is dominated by the automotive industry and is becoming more prevalent in other major manufacturing industries including aerospace. Nevertheless, a recent boost to the robotics and AI industry from the UK Government’s Industrial Strategy Challenge Fund, has unlocked a substantial opportunity for the UK to embrace the new robotics age. According to the UK Robotics and Autonomous Systems Special Interest Group, the UK could take a 10% market share of the global robotics industry within the next few years. Robotics and AI are already driving innovation in a diverse range of sectors where the UK has significant strengths, including healthcare, manufacturing, transport, aerospace and oil and gas.


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Focusing on these key areas, and accelerating development in this wide range of sectors will ensure that the UK leads not only in terms of scientific advances, but also in commercialisation and competitiveness. Healthcare, for example, is becoming a extremely important area of development in the use of robotics and AI. There are a number of innovative robotics companies already operating in the UK and the development of bionic limbs is currently being pioneered by a British robotics company who use 3D body scanning and printing to create bionic hands that are advanced, lightweight and low-cost. The possibilities for manufacturers in the robotics sector are growing and it is now an important time for the UK to expand its presence in the sector. Robotic manufacturers aiming to put innovative ideas into research and development and then through to production, however, are dependent on expensive, custom-made equipment of high specification which can be difficult to acquire without having to commit scarce capital. Against this backdrop, access to a range of smart and appropriate financing techniques –Finance 4.0 – is critical to a company’s ability to sustainably invest in the new fourth-generation of digitalised technology and automation equipment.

Finance 4.0 covers a range of requirements from the acquisition of a single digitalised piece of technology, right through to financing a whole new factory. These financing methods can help make the upgrade to digitalised technology affordable and potentially cost neutral (or better) for the manufacturer. Finance 4.0 arrangements tend to be offered by specialist providers, such as Siemens Financial Services, that have a deep understanding not only of how the digitalised technology works, but also of how that technology can be practically implemented. The benefits of development in the robotics sector are significant and far-reaching, meaning that manufacturers are racing to keep up with multiple and continuous technological trends and advancements. To best navigate these, such companies should consider working with a specialist financier to help them understand the most sustainable ways to invest in Industry 4.0 technology. Whilst this can be a challenge, companies that delay investment and fail to embrace the opportunities available to them, risk being left behind by the competition.

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With greater investment from healthcare organisations and surgical robot technology about to become generic, the conditions are perfect for a boom in the surgical robotics market. But how can design engineers and technical medical staff ensure these new systems operate reliably and safely? Michele Windsor, global marketing manager at surgical robot battery manufacturer Accutronics, has a solution. While they may sometimes feel like a new medical technology, surgical robots have actually been around for several decades. The first robot system successfully conducted a neurosurgical biopsy in 1985, while the US Food and Drug Administration (FDA) approved its first surgical robot — the da Vinci surgical system — in 2000. However, it’s only in the past few years that we’ve seen this technology really take off. In the UK, the number of surgical robots used in prostate cancer centres at NHS hospitals tripled between 2010 and 2017. The NHS subsequently invited companies to tender for a £300m surgical robot contract in January 2018, showing that the number of robot surgeons in the UK will continue to grow in the coming years. This same growth is happening across the world, and the popularity of the da Vinci system is an effective barometer of the growing popularity. According to Intuitive Surgical, the company behind the system, the da Vinci robot had sold 4,271 units globally as of September 30, 2017. More than 50 per cent of these were installed in the US alone.


PECM Issue 33

As The Economist reported in 2017, many of Intuitive Surgical’s patents are due to expire soon, which will bring with it greater competition from start-ups and established companies. This is ideal for the prosperity of the robot market and will improve the precision and effectiveness of complex, minimally-invasive surgeries. However, it does bring challenges with it. If new companies enter the surgical robot market, it is critical that those systems are designed to the same quality and safety standards as those produced by companies with more experience. This means that design engineers working on the project must understand the importance of each component in the system, especially critical back-up power components such as batteries. Traditionally, robot systems have used sealed lead acid (SLA) batteries as a back-up power source. This is because, in hospital environments with increasingly complex electrical requirements, AC power alone is not always reliable. The critical nature of the application means that even a momentary loss of power can have disastrous, even fatal, consequences. However, the traditional SLA batteries used in robotic systems have their drawbacks. The batteries are bulky and unwieldy, offer relatively low energy density and require frequent maintenance and servicing every two years. When you consider the associated costs of this, it makes for a relatively high total cost of ownership — which is understandably undesirable for healthcare

environments where a strong return on investment is important. Fortunately, new movers into the surgical robots market have an opportunity to bypass these traditional problems by designing smart SLA replacement batteries into the system. For example, Ultralife Corporation’s lithium iron phosphate (LiFePO4) technology has a similar charging method as SLAs, but with an inherently safer chemistry, a service life of five to seven years and an internal battery management system (BMS) that ensures protection from over-charging and overdischarging, which can cause damage over time. The role of design engineers in ensuring the safety of the next generation of surgical robots is to consider the proper critical backup power-supply early in the design process. By considering alternatives to traditional SLAs, design engineers can help their projects outperform traditional systems, for longer, while maximising patient safety. With a surge in the number of medical technology manufacturers active in the surgical robot market likely to occur in the coming years, now is the ideal time for design engineers to consult with a robot battery specialist like Accutronics or Ultralife Corporation to ensure their project is a success. For help choosing the right smart battery for your robot, contact Accutronics on +44 (0) 1782 566 688

ADVANCED AUTOMATION BY THE SOLDERING EXPERTS More than half a century of experience in soldering and superiority in innovation, allows us to take our customers to the next step in achieving production excellence. The new WTBR 1000 Benchtop Robot represents a one-of-akind synergy of precision, reliability, and productivity of soldering tasks. Highest soldering precision and superior reliability The WTBR 1000 is equipped with Weller‘s high performance Technology Line soldering tools, ensuring consistent quality of solder joints. The solder feeder is designed to be in close proximity to the workpiece (PCB), pulling the wire rather than pushing it through the feeder tube. The robust and sturdy construction ensures that no sudden movements or vibrations negatively


affect the workpiece, the components or the tools. Maximizing productivity, lowering cost A double drawer system allows continuous production thereby providing much higher process throughput, improving productivity and offering flexibility. The WTBR 1000 allows up to 50% cost saving versus hand soldering. Easy to learn and use software The WTBR 1000 is operated with easy to learn and use software, enabling operators to start using the unit comfortably and quickly.

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Issue 33 PECM





Nissan, an official sponsor of the UEFA Champions League Final Kyiv 2018, showcased an innovative technology to encourage and excite grassroots football with the world debut of Pitch-R, an autonomous robot that uses Nissan’s ProPILOT driver assistance technology to create a football pitch wherever there’s space. With onboard four-camera vision, GPS location tracking and collision avoidance systems, Pitch-R draws lines on grass, tarmac or gravel with eco-friendly dissolvable paint. The whole process can take less than 20 minutes. ProPILOT is a key part of Nissan Intelligent Mobility, the company’s vision for changing how cars are driven, powered and integrated into society. Nissan recently started delivering the new Nissan LEAF, the icon of Nissan Intelligent Mobility, in Europe. More than 34,000 European customers have chosen the 100% electric new LEAF, which has earned a 5-star safety rating from the European New Car Assessment Programme. Nissan also showcased a world-first prototype technology in Kyiv that will enable cars to learn from their drivers. The company’s Brain-to-Vehicle system interprets the driver’s brain waves to predict what actions they intend to take next.


PECM Issue 33

For example, by recognizing whether a driver is about to brake or turn, the technology enables a vehicle to initiate the action between 0.2 and 0.5 seconds earlier. This increases safety and comfort for drivers, giving them more confidence. The UEFA Champions League Final in Kyiv marked Nissan’s fourth year as an official sponsor of the competition. The partnership was recently extended to the next cycle 20182021. Nissan’s engagement with grassroots football also includes support to programs that help young people not currently in education or training. The purpose is to harness the power of football to create a fairer society and brighten the futures of young people across Europe. The program is operating in both France and the U.K. through a partnership with the UEFA Foundation for Children and StreetFootballWorld. Nissan used the UEFA Champions League Final Kyiv 2018 to inspire seven young people from two grassroots organizations – Sports Dans La Ville (France) and Street League (U.K.). Nissan gave them the chance to attend the final and meet UEFA football players.

About Nissan in Europe Nissan has one of the most comprehensive European presences of any overseas manufacturer, employing more than 17,000 staff across locally-based design, research & development, manufacturing, logistics and sales & marketing operations. Last year Nissan plants in the UK, Spain and Russia produced more than 660,000 vehicles including award-winning crossovers, commercial vehicles and the Nissan LEAF, the world’s most popular electric vehicle. Pursuing a goal of zero emissions and zero fatalities on the road, Nissan is leading the field with its vision of Intelligent Mobility. Designed to guide Nissan’s product and technology pipeline, this 360 degree approach to the future of mobility will anchor critical company decisions around how cars are powered, how cars are driven, and how cars integrate into society. Nissan is positioned to become the most desirable Asian brand in Europe.

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RETROFIT YOUR FUTURE You can’t teach an old dog new tricks. In almost every country, an expression exists to mean that it’s difficult to change the way something is done, if it has been that way for a long time. Despite the popularity of the phrase, it does not apply to industrial machinery. Retrofitting allows legacy equipment to learn new tricks at an impressive rate. Here, Jonathan Wilkins, marketing director at supplier of industrial obsolete parts EU Automation, explains why retrofitting is so important to Industry 4.0. Industrial machinery has a long lifespan. In many facilities, equipment will be in operation for 15 to 30 years, as it is designed to be robust and long-lasting. Legacy equipment can function effectively for decades, but its capabilities will fall behind newer counterparts. Older machines or components may be less efficient, have less computing power and less memory to store and record data. They could also offer limited connectivity and may even operate with a different language protocol. These differences can make it difficult to make outdated equipment compatible with new industrial computers or programmable logic controllers (PLCs).

Thankfully, these capabilities don’t have to be built into a machine, meaning that if you want to reap the benefits of Industry 4.0, you don’t have to build an entirely new factory. This is good news, particularly for small and medium enterprises (SMEs), who are unlikely to be able to afford large amounts of new equipment. Retrofitting adds new capabilities or functions to equipment, that it didn’t have when originally designed and built. It could be a case of adding a connected sensor to a motor, or replacing older components with new, more advanced equipment. One of the most popular ways to do this is to add flexible modular devices to capture, process and transfer data. Retrofitting has become a large market, as it can improve energy efficiency, processing speeds, machine reliability, reduce the need for maintenance and extend system life. For example, Bosch Rexroth has used its Internet of Things (IoT) gateway to reduce costs by 25 per cent at one of its German facilities, by fitting production test risks, which took only four hours to fit. To get the most out of retrofitting, it should be a gradual and managed process.

What’s the catch?

Limited connectivity, communication and data storage creates a barrier to Industry 4.0. For a factory to be truly smart, machines must be able to communicate and make real-time decisions. This requires networking between individual components, machines, factories and even enterprises to collect, communicate, analyse and compare data. This information can then be used for predictive analytics or to optimise processes.

Though retrofitting makes it possible to connect legacy equipment to the Industrial Internet of Things (IIoT), it can be challenging to implement across a facility. Old equipment can be difficult to digitalise and connect, as they were not designed to do so. Some legacy equipment may be poorly documented or understood, which can leave some uncertainty about what the consequence of a retrofit will be.

Monitoring equipment’s efficiency and using advanced diagnostics means machinery will be less likely to cause unplanned downtime. Facilities relying on aging, unconnected infrastructure can suffer huge production losses if components fail and manufacturing is halted.

Because equipment in factories has often come from different vendors and operates to different communication platforms, it can be difficult to connect it to the system and to each other. Interoperability can therefore be a huge hurdle for companies migrating to smarter methods of production. Engineering staff must maintain a huge amount of knowledge to optimise heterogenous systems.

Retrofitting to Industry 4.0 The advantages of Industry 4.0 are vast. Connected factories can be made more flexible, be monitored remotely, offer an improved workplace for staff, facilitate predictive analytics and more. The bottom line is that data must be gathered, turned into information and communicated to achieve this.


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Manufacturers must take security into account when retrofitting, because adding a new application to an old system could introduce security risks if the system was not designed to be connected to the internet.

Where do I start? Well structured retrofitting, rather than random patching, is the best way to future proof your upgraded factory. Simply monitoring whether equipment is on or off and how much the system is producing can give you an indication of effectiveness and performance. One example is the Pepperl+Fuchs smart bridge adapter, which enables process data collected by field devices to be communicated with a mobile device via Bluetooth. This connects information which would usually have remained in the machine to facility staff, who can then make use of it in maintenance. Quick gains can also be made by connecting older machines to the internet, using connected sensors. This can connect to a controller, which collects data and converts it to a usable format, such as OPC-UA, so the information can be made available to the rest of the factory network. Businesses have been quick to tap into this trend, with organisations like Bosch, SKF and Festo all offering retrofitting solutions to increase the connectivity of legacy equipment. To reap the benefits, companies need to determine what influences product quality, downtime and efficiency. They can then retrofit sensors to measure and communicate the information to higher level systems, teaching old equipment new tricks.

About EU Automation: EU Automation stocks and sells new, used, refurbished and obsolete industrial automation spares. Its global network of preferred partner warehouses, and wholly owned distribution centers, enables it to offer a unique service within the automation industry, spanning the entire globe. It provides worldwide express delivery on all products meaning it can supply any part, to any destination, at very short notice.


VELDEN ENGINEERING Further to Velden’s recent announcement of their acceptance on the Knowledge Transfer Programme with Manchester Metropolitan University, Riku Das, a recent graduate of Software Engineering BSc at the University of Huddersfield, has joined the company to commence the 36month project. Riku is tasked with further developing their in-house designed ERP system, Vmans. Originally designed and developed by the Managing Director, Austin Kitchen, Riku will be building on the legacy of the current system by future proofing the application with the use of newer technologies, including cloud hosting, machine learning (AI) and by developing an Internet of Things framework to assist in Velden’s mission to become a truly smart factory. Velden, a subcontract precision engineering company based near Manchester, have been working towards Industry 4.0 practices for several years and their commitment is evidenced by consistent investment in processes including comprehensive machine monitoring, EDI direct data interchange with their customers, the use of

factory automation including robot loading, cutting edge machinery, camera and laser vision inspection systems and intelligent energy saving LED factory lighting. This significant investment will ensure Velden remain at the forefront of their industry. 01204 520620

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Rockwell Automation is joining industry leaders ABB, Belden, Bosch Rexroth, B&R, Cisco, Hilscher, KUKA, National Instruments, Parker Hannifin, Phoenix Contact, Pilz, Schneider Electric, TTTech and WAGO (collectively known as Shapers) to create a communication solution for real-time and sensor-to-cloud applications in industrial operations. The solution will be based on the OPC UA protocol, which allows easy and secure sharing of information across different vendor technologies and the time-sensitive networking (TSN) suite of standards, which helps improve latency and robustness in converged industrial networks. “Connecting technologies across an industrial organization while maintaining multivendor interoperability requires a harmonized, interoperable solution that uses consistent information models, communication and application behavior (together known as application profiles),” said Paul Brooks, business development manager, Rockwell Automation. “That’s what this group of automation leaders are combining their expertise to create.


PECM Issue 33

Our solution will give manufacturing and industrial organizations best-of-breed I/O device control, motion and safety application profiles,” said Sebastian Sachse, B&R Industrial Automation. To ensure the emerging OPC UA TSN solution supports interoperability of different vendor technologies on the same network, the companies are engaging with industry consortia such as Avnu, IEEE, IIC, LNI 4.0 and OPC Foundation. The companies are also planning an announcement in the coming months on how to achieve unified application profiles, which is the last hurdle to device harmonization. They aim to provide one-stopshop certification of the overall solution up to the device-profile level. The companies have already published whitepapers on OPC UA TSN technology, such as an IIC whitepaper on converged traffic types. They have also made significant contributions to the recently released PubSub extension of OPC UA, and plan to set up a collaboration between the IIC and LNI testbeds.

About Rockwell Automation Rockwell Automation Inc. (NYSE: ROK), the world’s largest company dedicated to industrial automation and information, makes its customers more productive and the world more sustainable. Headquartered in Milwaukee, Wis., Rockwell Automation employs approximately 22,000 people serving customers in more than 80 countries.

Distributor of Mean Well Din Rail Power Supplies

Electrical & Electronics



Over the summer months Robot Wars has been Guhring. The Guhring 245 Series Taper Shank Drill back on our TV screens with 40 distinct combat has been used throughout the series as a tactical Electro-wind’s DC power supply units provide the power service departments or large logistics centre, these units robots battling it out for the prestigious accolade feature in battles with contestants. Manufactured required to a trailers moving deck lift, tail lift and internal can be produced to customers particular requirements. of being crowned the 2016 champion. Self-built by Robo Challenge, a Birmingham based company lighting when unaccompanined by a tractor unit for by the competitors and fighting in a purpose-built of enthusiastic, creative andunits downright whacky All Electro-wind’s 24VDC are designed and loadingthe andsix-episode unloading. series has been watched by engineers, Sir Killalot just one of many which arena, manufactured in the is companies UK workshops, over 2 million people each week. prestigious projects thattimes Robo has promotes short lead andChallenge greater flexibility Due to the phenomenal growth of the e-commerce delivered. business, companies are expanding their fleet The Grand Final was won by Apollo, a and robot can be manufactured supply single or multiple As wellUnits as featuring heavily in thetohit TV show with captained driven byenvironment Dave Young. As one warehouseand capacity. Their impact andofcarbon bays. Power supply accessories and spareswith including DC the House Robots that featured inofthe Series, DC Sir Sir Killalot, Robo Challenge was also tasked footprint can be reduced by the use a bespoke extension leads, connectors junction boxes are also Killalot is a 740kg robot with a 2.5tonne pincer designing and manufacturing theand coveted trophy. power supply. available. grip and a top speed of 10mph. On one arm is a A trophy that has another iconic masterpiece at its The units have recharging down time, plugged directly 300kg arm lift no that outweighs all competitors and centre, the Guhring 245 Series Drill. intothe theother mains,arm whether working in maintenance and on is a 2inch taper shank drill from

SWITCHTEC’S ENCLOSED FUSED SWITCH THE ALL-ROUND SOLUTION ® OFFER A COMPACT DISCONNECTORS ELECTRICAL & ELECTRONICS FOR AUTOMATIC DOCKING SOLUTION WITHOUT COMPROMISING ON The intelligent path to customer-specific connections: ODU-MAC – our versatile modular connector solution QUALITY enables the transmission of power, high current, high


Compact modular connector system

Now available with Rotary Isolator and separate Fuse Holder, Switchtec’s NTFS enclosed fused switch disconnectors offer improved performance at a more competitive price. The NTFS Fused Switches use the industry standard combination of Rotary Isolator linked to a DIN rail mounted fuse holder fitted into an IP65 metal enclosure. This enables Switchtec to offer a cheaper solution whilst maintaining the use of high quality components ensuring there is no compromise on quality.

voltage, coax, high-speed data, fiber optics and other media such as air or fluid. packaged enclosures are available in ratings For your made-to-measure connection.

32A, 63A, 80A and 125Amp ex-stock.

All of the NTFS enclosed fused switch disconnectors are supplied in a high quality IP65, RAL 7035, pale grey painted, mild steel enclosure and for versatility, they have removable top and bottom gland plates. The switches offer an IP20 level of internal protection with their touch proof terminals. They have a door interlocked, padlockable facility deployable in the operating handle ‘off’ position and are supplied with a door earth lead. All products conform to IEC60947-3, are certified by UL, EAC, CCC, and are CE approved.

As a result of Switchtec’s experience and knowledge of the marketplace, its vast Aimed at electrical contractors, equipment supplier network and buying power, it is manufacturers and machine builders, able to source the components at a more the fused switch disconnectors provide a competitive price and passing this on to its ® solution where general switching duties are customers. Fitted with high quality Telergon New ODU-MAC strain relief housing required. switches & Mersen Fuse Holders, the


PECM Issue 33

Fail-safe performance thanks to outstanding contact reliability 6 standard docking solutions They are suitable for control switches for High packing density multiple circuits and for use in resistive load 30 different high-speed inserts for in the field of applications as main circuits machines, data technology heating equipment, lighting, ventilation and air-conditioning. Up to 100,000 mating cycles

Stable low contact resistance field sales Switchtec’s knowledgeable engineers are available to provide ODU-MAC strain relief housing for optimal application advice and product choice protection as are the company’s in-house assistance sales and design team. Tel: +44 (0) 1785 818600 E-mail: Fax:Ltd. +44 (0) 1785 811900 ODU-UK Web: Phone: +44 1509 266433

Issue 23 PECM


NEW iso685

Insulation Monitoring Device Monitor, Report, Predict, Prevent

Innovative insulation monitoring for maximum system availability Early identification of earth faults in mission critical AC or DC control and auxiliary supplies can prevent equipment shutdown, increase production output and improve profitability.


Low Mill Business Park Ulverston, Cumbria, LA12 9EE Tel: 44(0) 1229 480123 email:




About Bentley Motors Bentley Motors is the most sought after luxury car brand in the world. The company’s headquarters in Crewe is home to all of its operations including design, R&D, engineering and production of the company’s four model lines, Bentayga, Continental, Flying Spur and Mulsanne. The combination of fine craftsmanship, using skills that have been handed down through generations, alongside engineering expertise and cutting-edge technology is unique to UK luxury car brands such as Bentley. It is also an example of highvalue British manufacturing at its best. Bentley employs around 4,000 people at Crewe. Bentley Motors today announces that construction has started on the UK’s largest ever solar-powered car port at Bentley’s factory headquarters in Crewe, UK. The installation of 10,000 solar panels, which has a capacity of 2.7MW, will take approximately six months to complete. Once completed, the car port - which covers Bentley’s colleague car park - will take Bentley’s energy system to 30,815 solar panels. This includes the 20,815 panel roof top installation completed in 2013. Commenting on the installation, Peter Bosch, Bentley’s Member of the Board for Manufacturing, said: “We continue to focus on new initiatives that reinforce our commitment to the environment, whether this is introducing alternative powertrain technologies in future models, or our award-winning work to reduce the environmental impact of our factory.


PECM Issue 33

“This solar installation is another example of how we can make our factory more sustainable by using technological innovation. This helps us produce extraordinary cars with responsiblysourced materials in an efficient manner, while continually striving to reduce the company’s environmental impact.” The solar car port installation, which covers 1,378 car parking spaces, and an area of 16,426m2, will be installed and operated by FlexiSolar, the innovative solar car port specialist. The project is also backed by Innovate UK, the UK’s innovation agency driven to support the science and technology initiatives that will grow the UK economy. This solar installation announcement follows recent recognition that Bentley Motors has become the first UK automotive manufacturer to be awarded the Carbon Trust Standards for carbon, water and waste, further reducing the environmental impact of its operations in Crewe.

About FlexiSolar FlexiSolar’s vision is to integrate three core technologies to reduce customers costs and to help decarbonise energy generation and transport. With an expert team benefitting from over 100 years working in the solar industry and the wider renewables sector, the design, manufacturing, installation and operations company focusses on offering innovative solar carport solutions, integrated with battery storage and electric vehicle charging infrastructure.


DRALLIM WORKING WITH DV POWER Batteries are crucial components in the overall reliability of powerplants, substations, telecommunication systems, generator excitation systems and protection & control systems. The inability of a battery string to provide sufficient voltage/power to protection circuits may lead to catastrophic consequences that cause damage to site equipment, resulting in reduced safety and costly downtime. Listening to the demands of test engineers from around the world, DV Power have developed state-of-the-art battery testing and monitoring solutions to meet IEEE and IEC standards alongside a wide range of customer specific test procedures. The essential test for the condition assessment of a battery string is the capacity test which can be carried out using the BLU series of Battery Load Units. In addition to this critical test the DV Power portfolio of battery test equipment is designed to measure and monitor intercell connection voltage, internal resistance, cell and ambient temperature and cell voltage. On completion of testing the DV Power BAC25A Battery Charger can be used to rapidly recharge the tested lead-acid and Ni-Cd batteries.

DV Power are renowned for using cuttingedge-technology to produce light, powerful, and highly accurate battery, circuit breaker and transformer test equipment. Intuitive controls allow for manual and fully automated test procedures. Easy to use analytical software ensures that DV Power test instruments are efficient whilst remaining user friendly. DV Power are represented in the UK and Ireland by Sussex based Drallim Industries

Ltd whose team of experienced engineers offer full product support. DV Power provides a 3-year warranty on all test instrumentation. This is a guarantee to our customers that they will receive the highest quality test equipment on the market.

Email: | Tel: 01424 205140 | Web:

RMO-H-Final.pdf 1 22/06/2018 15:34:58

New patented technology! In 2018 DV Power delivered the first handheld micro ohmmeter (< 1 kg), which generates up to 300A regulated DC current










In 2003 DV Power launched the world’s first 500A portable micro ohmmeter - 8 kg

RMO500A Representing DV Power in the UK and Ireland

Drallim Industries Limited

Millwood House, Drury Lane | Ponswood Industrial Estate St. Leonards on Sea | East Sussex | UK | TN38 9BA Tel: +44(0)1424 205140 | Email: | Web: (When enquiring please quote PECM )

Issue 33 PECM


General purpose accelerometer with internal temperature sensor Wilcoxon’s data collector powered dual purpose 786T sensor measures both acceleration and temperature. This is useful for acquiring data with any one of the many portable analyzers for collecting predictive data for vibration spectrum analysis. The temperature sensor is powered through the accelerometer powering circuit and provides the DC voltage output proportional to the temperature in degrees Celsius. Top exit, general purpose, dual output with temperature, 3 pin MIL-C-5015 connector, case isolated, 100 mV/g, ±5% sensitivity tolerance. Key features – rugged design, corrosion resistant, hermetically sealed, case isolated, ESD-protected and reverse wiring protection.

Eland Cables Eland Cables has launched Veriflex®, its own brand of control and BUS cables for industrial applications. BSI Kitemark approved, extended warranties across the range, available for next day delivery with no price premium described as “affordable excellence” Paul Turner, BSI Certification Technical Expert recognises the Kitemark as a new benchmark in cable compliance “As the first company to achieve the BSI Cable Batch Verification Kitemark, Eland Cables sets a new benchmark in cable compliance. The rigorous and extensive testing programme they undertake tests the cables to British and international standards for key safety criteria. By certifying their cables against the scheme, Eland Cables can demonstrate that its cables meet the highest standards.” For more information tel. 020 7241 8787 or email

Harsh Environment High Power Connector from Foremost has optional hinged cover for maximum protection Foremost Electronics, the Essex based specialist distributor of electromechanical components, announces the availability of the latest addition to the Binder HEC (Harsh Environment Connector) series of connectors designed specifically for outdoor use. The new Series 696 HEC power connector power connector is capable of handling up to 32A at a rated voltage of 600V and is available in both cable and panel mount formats with 4+PE silver plated male or female contacts. Introduced by Foremost at the same time is a matching panel-mount connector with a hinged cover for maximum protection when not mated.

KDP Electronic Systems 01767 651058

New expansion units for Eco-POWER METER KW2M The eco-POWER METER KW2M and its expansion units monitor various parameters as well as electricity within factories and facilities. No PLC is required to track data concerning air, water, pressure, temperature, illuminance, production quantity, operation status ON/OFF, etc. This environmental and production information can help you to analyse and improve your energy consumption and productivity. In commercial complexes, the KW2M Eco POWER METER helps to maintain the comfort of the people inside the building and ensures early detection of abnormalities by monitoring variations of energy consumption and temperature on each floor or in service rooms. If there is an unbalanced load due to a V-connected transformer or a heater, a voltage imbalance occurs between phases and the motor torque becomes insufficient, which causes a rise in heat or a reduction in the product lifetime.


PECM Issue 33

Trizo is delighted to announce the implementation of another SMT Pick and Place line at our Bridgwater manufacturing facility. Trizo chose to invest in a Europlacer iineo II SMT line to compliment the production facility. This gives Trizo the opportunity to offer greater manufacturing flexibility, faster and accurate placement of components. The new line was fully commissioned in September 2017, just before Trizo’s 10th Anniversary celebrations. This investment in advanced technology will keep Trizo Ltd competitive, allowing cost savings by shortening the manufacturing lead-time to assemble boards.Trizo are accredited to AS9100 Rev D and manufactures assemblies for a number of different industries including, Aerospace, Automotive, Medical, Nuclear and Industrial customers. To learn more about Trizo Ltd, contact 01278 455 344

Powerstax Powers Carbon Capture Installation Powerstax, one of Europe’s leading valueadded and industrial power solutions manufacturers has supplied a high power rectifier system to leading waste management company Future Environmental Technologies Ltd., for a carbon capture installation at a factory in Wales. The installation allows the end user to its reduce C0₂ emissions and store and sell recovered commercial grade C0₂ for other applications. “We were approached by Future Environmental Technologies (FET) to discuss a carbon capture application which at the beginning presented us with many unknowns” Comments Tim Worley, CEO of Powerstax. ”At our initial concept meetings we started to determine a specification for the power requirements of the system but output voltage was still not determined as it was dependent on the requirements of the chemistry utilised in the carbon capture cells.” For more information contact or visit

VTM UK Ltd Irvin House Icknield Way Letchworth Garden City Hertfordshire SG6 1EF

01462 473820

Scan to call

Carbon Film Metal Film High Power Metal Oxide Flameproof Jumper Carbon Comp Anti-Surge Wire Wound MLCC Chip Cap Thick Film Thin Film Pulse Anti Sulfur High Power High Voltage Current Sense Precision

12 wks 12 wks 12 wks 12 wks 12 wks 12 wks 19 wks 12 wks 15 wks

6 wks 12 wks 12 wks 12 wks 12 wks 12 wks 12 wks 12 wks 12 wks


Metal Film Melf AEC-Q200 Melf Precision Melf High Current Shunt ESD Suppressor Foil On Ceramic Electrolytic Caps

24 wks 28 wks 28 wks 18 wks 18 wks 14 wks 14 wks

VTM UK Ltd UK office / stores. Realistic lead times and prices. Every Form and fit available. Call or email for more information.

01462 473820

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quaterpageadapril18-2.qxp_Layout 1 18/04/2018 10:01 Page 1

KAIZEN TECHNOLOGY You think it, we build it!








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01763 249666



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Issue 33 PECM




EFFECTIVE CONTROL AND AUXILIARY CIRCUIT MONITORING REDUCES DOWNTIME AND INCREASES PROFITABILITY Early identification of earth faults in mission critical AC or DC control and auxiliary supplies can prevent equipment shutdown, increase production output and improve profitability.

Unearthed IT Power Systems An unearthed IT system as per BS7671 section 3 and IEC60364-4, is tolerant to first earth fault and will not cut power, unlike a TN system which would cause a power failure - therefore an IT system makes it more reliable and safer for mission critical systems, protecting both production and people. The ungrounded system has no direct connection between live conductors and earth. The system does not shut down when the first low R earth fault occurs, which means the power supply is maintained. An IT system is used widely in critical applications like Group 2 Medical locations and AC/DC auxiliary circuit applications for more effective protection, control and tripping supply in substations/power stations. IT systems are particularly appropriate for auxiliary circuits where high reliability is required - see BS7671 557.3.4.1 Note 2. However, the full benefit of an IT system can only be realised by detecting development of the first earth fault and repairing it before it develops to a second earth fault on a different conductor. That requires an Insulation Monitoring Device (IMD) which performs best when paired with a fault location system (iFLS) which enables maintenance teams to easily find the faulty circuit.

Insulation Monitoring Device (IMD) in Unearthed IT Systems BS7671 clause 411.6.3.1 states “Where an IT system is used for reasons of continuity of supply, an insulation monitoring device shall be provided...” Neutral conductor N and ground conductor PE are connected via a bonding jumper. First low R earth fault results in disconnection of supply.


PECM Issue 33

Effective Control and Auxiliary Circuit Monitoring Can Reduce Downtime and Increase Profitability

conductiveAllparts liable to cause malfunction The governing standard of the Insulation The governing standard of the Insulation IMDs must be labelled to highlight system of monitoring device (IMD) is BS EN as perinadvertent use i.e AC, DC or AC/DC. of the controlled operation) monitoring device (IMD) is BS EN 61557-8 as61557-8(e.g. IEC 60364-4 and BS7671 557.3.4.3. and 538.1.1 per IEC 60364-4 and BS7671 557.3.4.3. and equipment.” BS EN 61577-8 prohibits use of passive devices 538.1.1 in an IT circuits which cannot detect symmetrical All IMDs must be labelled to highlight faults. A symmetrical fault is particularly dangerous to control circuit because it can lead to inadvertent system of use i.e AC, DC or AC/DC. BS EN 61577-8 prohibits use of passive switching or false trippping without detection. The below shows adetect double high resistance devices in an IT circuitsdiagram which cannot Insulation monitoring technology combined symmetrical insulation fault on DC PLC circuit. The symmetrical faults. A symmetrical fault is passive device and fault is not detectable by the with earth fault location systems developed can therefore cause switch to be seen as closed. particularly dangerous to control circuit Insulation monitoring technology combined bycircuit Bender are in asystems widedeveloped range by of with employed earth fault location BS7671 clause 557.3.201 states: “A control because it can lead to inadvertent switching Bender are employed in a wide range of critical shall be designed, arranged and protectedcritical to limit control circuit applications within control circuit applications within industry dangers resulting from a fault between the control or false trippping without detection. sectors that cannotcannot afford unscheduled circuit and other conductive parts liable to cause industry sectors thatsimply simply afford The diagram below shows a double high operation) of the shutdowns or interruptions in production and malfunction (e.g. inadvertent unscheduled shutdowns process operations. or interruptions in controlled equipment.” resistance symmetrical insulation fault production and process operations. on DC PLC circuit. The fault is not detectable by the passive device and can therefore cause switch to be seen as closed. BS7671 clause 557.3.201 states: “A control circuit shall be designed, arranged and protected to limit dangers resulting from a fault between the control circuit and other BENDER UK Low Mill Business Park, Ulverston, Cumbria, LA12 9EE

Tel: 44(0) 1229 480123 Tel ROI: +353 1 5060611

T m I

B i f t s d s f c

B s d c m c

The governing standard of the information Insulation to deliver effective predictiveAll and IMDs must be labelled to highlight s preventive maintenance that avoids shutdowns, f Battery ability to provide load current monitoring device (IMD) is BS EN 61557-8 perincreases productivityuse reduces as downtime, and i.e AC, DC or AC/DC. f Battery in service monitoring improves profitability. IEC 60364-4 and BS7671 557.3.4.3. and 538.1.1

Feature BA 300 BS EN 61577-8 prohibits use of passive devices Comply with EN 61557-8 No in an IT circuits which cannot detect symmetrical No faults. A symmetrical fault is particularly dangerous Detection of symmetrical faults (Passive, voltage imbalance principle) to control circuit because it can lead to inadvertent Insulation trippping faults in AC/DC mixed circuit I,e switching or false without detection. The No involving battery charger, UPS diagram below shows a double high resistance resistance value 5K-90K Ohms symmetrical Measured insulation fault on DC PLC circuit. The Self-test and checks for IR No fault is not detectable by the passive device and location system as per IEC 61557-9 No can thereforeFaultcause switch to be seen as closed.

Bender IMD Yes Yes

Yes (full) 1K – 20M Ohms Yes Yes (optional)

Insulation monitoring technology co Tel: 44(0) 1229 480123 with earth fault location systems devel BS7671 clause 557.3.201 states: “ANocontrol circuit E/F detection in de-energised circuit Yes Bender are employed in a wide range o shall be designed, arranged and protected to limit control circuit applications within dangers resulting from a fault between the control An alternative way of monitoring for earth faults is by using a Earth fault alarm is an optional function on BA300 and shouldn’t sectors that simply cannot circuit and passive othermeasurement conductive parts liable to does cause principle, although this method not be included with an external earth fault monitoring system. afford unsc of earth fault detection on an IT system isin product the IEC61557-8 regulations for insulationof monitoring shutdowns or features interruptions malfunctioncomply (e.g.with inadvertent operation) the Comparison devices. shown below. operations. controlled equipment.” Tel: 44(0) 1229 480123 Tel ROI: +353process 1 5060611 Availability of measured value



BENDER UK Low Mill Business Park, Ulverston, Cumbria, LA12 9EE

Battery management system such as a BA 300 provides the following monitoring functions compared with IMD: • • • • •

Knowledge is power

The benefits of using insulation monitoring technology to enable early identification of earth faults in mission critical AC or DC control and auxiliary supplies cannot be underestimated.

Over and under voltage conditions High impedance alarm Earth fault alarm Battery ability to provide load current Battery in service monitoring

Continuous monitoring equips maintenance teams and plant operators with the vital information to deliver effective predictive and preventive maintenance that avoids shutdowns, reduces downtime, increases productivity and improves profitability.

IP67/68 Rated Waterproof

Coaxial Cable Assemblies

Waste Mgmt.




Perfectly suited for harsh environments such as Waste Management, Agriculture Technology, and many others. Issue 33 PECM




BREAKTHROUGH TECHNOLOGY MAKES CONNECTIVITY EASY – EASY MATING, EASY CLEANING, EASY INTEGRATION – WITH BRAND-NEW FISCHER FREEDOMTM SERIES Fischer Connectors, the global connectivity solution provider of high-performance circular connector and cable assemblies, continues to push the boundaries of technological innovation in rugged miniaturization, high-speed data transmission, sealing, and wearability. Committed to making its customers’ lives easier, on 11th June 2018 Fischer Connectors has launching a breakthrough plug & use connectivity technology with its new product line: the Fischer FreedomTM Series and its first product: the Fischer LP360TM. The Fischer FreedomTM Series revolutionizes wearable connectivity, as it meets design engineers’ urgent needs for designing and connecting portable and body-worn applications quickly and easily, thanks to three breakthrough technology innovations: •

Mating – no key code allows for 3600 mating “freedom”

Locking – ball-locking mechanism with sealing and variable pre-defined force (patent pending)

Materials – specially designed pins on the plug are IP68 sealed with a membrane (patent pending)

Thanks to these innovations, the Fischer FreedomTM Series facilitates integration, maximizes usability and optimizes cable management for a wide variety of applications within markets such as defense, security, medical, industrial and civil engineering – to name just a few. “Our core mission at Fischer Connectors is to make our customers’ lives easier with a collaborative approach and tailored connectivity solutions,“ says Jonathan Brossard, Fischer Connectors Group’s CEO. “The creation of the Fischer FreedomTM Series is evidence that our mission actually strengthens our customers’ abilities to design for their markets. Reimagining connectivity like we’ve shown in the new Fischer FreedomTM Series allows those customers to turn their ambitious ideas into solutions that fit their world and help them break into new markets as well.”


PECM Issue 33

The development of the Fischer LP360TM connector, the first product in the brand-new Fischer FreedomTM Series, has introduced a new approach to connectivity, and innovative engineering and technology in mating, in locking and in materials.

Threefold usability The new Fischer FreedomTM Series and the Fischer LP360TM set a new standard in usability, which is threefold. The new product line makes end users’ lives easier by reducing cognitive, weight and reliability burdens thanks to: 1. Easy mating. Mating the Fischer LP360TM becomes as intuitive as buttoning up a vest – without compromising on the highperformance reliability required in harsh environments. 2. Easy cleaning. The new connector is fully cleanable (both plug and receptacle), and is easy to use and maintain with a faster set up and improved durability.

The Fischer FreedomTM Series also makes the life of design engineers easier, as it meets their need to easily and seamlessly integrate connectors – with or without cables – into multifunctional portable or body-worn devices. 3. Easy integration. Thanks to its compact and low-profile design, the Fischer LP360TM is easy to integrate into clothing with devices and subsystems; via the panel-mounted plug interface, cables can even be removed completely, and the connector can be directly integrated into the housing of such devices as a camera, a sensor, a light, a GPS.

Tel: 0800 432 0301 (Freephone UK) +44 23 9245 9600



COLD LAST WINTER? ** POWERDOWN and Patented Radiator Enhancement

GREEN - RED - AMBER what it means

Sunflow is the only real kiln clay heating manufacturer in the U.K, and only one of very few in the world.

We do not stop there. ‘Powerdown' is an amazing feature highlighted by the LED light on the back of the heater. When the light is green the heater is not drawing electricity for heat. When the light is red, the heater is on full power. When the light is amber, the electricity draw is reduced by as much as 75%! Powerdown kicks in as target temperature is approached or when the heater is maintaining temperature. One day all electric heaters will be built like this.

Embedding elements into kiln clay is an exacting process more akin to craftsmanship. The process is carried out by a team of Sunflow experts. This process ensures that the enriched kiln clay heats up fast. Ensures a lasting, even heat release and accurately controlled by our advanced programmable, wireless system to reduce energy costs. The patented (granted 2017) enhancement system ensures that natural convection is maximised and greater efficiency is achieved as radiant heat is projected through the large outer surfaces of the heater.

Muscle Machine The stove will heat up to 20 square metres or a much bigger space if used as a supplementary heater or for background heat e.g. sixteen degrees centigrade. Features rear wheel brake and pull handle. Bespoke colours are available. Call 0800 158 8270 for details Built to order, delivery approximately 4 weeks.

Growing from their factory in Royal Wootton Bassett, Sunflow have expanded to become national installers of electric heating. With a network of friendly, nonpushy surveyors and thousands of installations right up to the northern Highlands of Scotland, they can serve all your heating needs. Unique in their field, being the only home grown British manufacturer, Sunflow are proud engineers and manufacturers of Low Energy Electric heaters, using the latest kiln clay core technology. The people at Sunflow are committed to providing electric heating systems that are energy efficient, clean, safe and reliable. Much of their work is removing and replacing old inefficient and difficult to control night storage heaters, but oil and LPG heating systems will also become obsolete, as we strive towards clean and environmentally friendly heating systems. Sunflow are committed to environmentally friendly practices, their environmental policy is as robust as their heaters and they are continually looking at ways to improve.

Issue 33 PECM




ROTARY VERSUS PLANETARY SURFACE GRINDERS Planetary grinders were given their name because the motion of the discs in the base resembles that of the planets around the sun. Here, Ed Biggs, regional sales manager at surface preparation expert National Flooring Equipment, explains the differences between planetary and rotary grinders and how to decide which type to purchase or rent. Surface grinders use horizontal discs mounted with an abrasive material — usually diamond — to grind and polish marble, granite or concrete surfaces. There are two main variants of the technology, rotary and planetary, categorised by the configuration of the discs on their bases. Traditionally, surface grinders were all rotary - their bases contained two or four discs that counter-rotated. Planetary grinders were introduced to the US in the 1990s. Unlike rotary grinders, their bases comprise of three small discs — the planets — which rotate in one direction. The discs are mounted to a single larger disc — the Sun — which rotates in the opposite direction. Contractors are now faced with the difficulty of choosing between the two configurations, to work out which would be most beneficial for the job at hand.

Making the choice The different configurations of the machines mean they are each suited to different applications. Rotary grinders are often the best choice for aggressive jobs because they are gear driven, giving them a high horse power. Their weight also enables them to make strong contact with the floor, an advantage in hard to complete jobs. Rotary grinders are more able to access corners because of the square shape of their bases, compared to the round bases of planetary grinders. Although Chinese manufacturers are beginning to produce gear driven planetary grinders, the majority are still belt driven. This, plus the fact that they are lighter than their rotary counterparts, makes them more suitable for less aggressive jobs, such as smoothing out concrete or preparing a floor for an epoxy coating. Planetary grinders create smaller scratch patterns, meaning they can polish floors with greater clarity. Therefore, contractors who do a lot of polishing work should consider a planetary grinder, as it may best suit their needs.


PECM Issue 33

Where to start There are approximately 50 manufacturers of planetary grinders, compared to just three or four manufacturers of rotary grinders. This is partly because it’s more expensive to manufacture rotary grinders, but also because surface polishing is a very common task, so there is a high demand for planetary machines. If you’re finding it difficult to choose, we recommend starting with a rotary machine due to their ease of use. However, if your job involves a lot of polishing, you may wish to purchase a planetary grinder to achieve a high-quality finish. Cost is not a critical factor when deciding between planetary and rotary grinders because the two types have similar prices.

The main factor affecting cost is the size of the machine. Rotary grinders come in just two sizes, whereas planetary grinders can be purchased in many different sizes, giving rise to greater variation in price. Contractors must assess their needs before deciding on which size is appropriate for them. With an awareness of the differences between planetary and rotary grinders and advice from a reliable supplier, contractors can more easily purchase or rent the most suitable machine for their requirements.


Reduced from £1,480 down to *£980 21st century portable electric heating featuring ‘**powerdown’ - with fast kiln clay storage (works with any tariff, just plug into your 24 hour sockets if you have E7 or E10). Powerful 2 kilowatt rating - ideal for home, workshop, studios, offices, workstations. Ideal economic emergency heating. Many central heating systems start to struggle when outside temperatures plunge below minus two degrees. With boilers roaring constantly to keep up, the extra wear and tear is costly in fuel and maintenance. Why not use a Sunflow electric stove to heat exactly where you are?




Paying by credit card? Telephone 0800 158 8270 during office hours and ask for Diana or Claire. Real people, real service. If you need primary electric heating discover our InvincibleTM range. 24 hour brochure line 0800 158 8272 British made in Wiltshire.

*includes free delivery if you live on mainland Great Britain and Isle of Wight. Other areas call 0800 158 8270 for a quote

Vibration Analysts; Worth their Weight in Gold Genuinely good vibration analysts are worth their weight in gold. But how do you create good vibration analysts? A good vibration analyst provides an early warning of faults, with a clear statement of what’s wrong, what must be done, and the urgency of the required action. Good vibration analysts are accurate and confident. How do you make a “good” vibration analyst? You train them at an Authorized Mobius Institute Training Partner Center. The difference is in the unique way we train them. In the old days, with “death-by-PowerPoint” presentations, the analysts just had to take the word of the instructor - “I know it is confusing, but take my word for it, this is how it is – and now we need to move to the next topic” is the attitude of too many instructors. People often came home from the course more confused than they were before. And sadly, this is still the case with the majority of (non-Mobius) courses today. But Mobius approved instructors are different. Mobius Institute approved instructors use training materials rich with 3D animations and sophisticated simulations – hundreds of them! The animations and software simulations explain the machinery failure modes, the vibration signals, signal processing, and the instrumentation. They make everything crystal clear. To achieve the best possible results, without extra charge, students attend online training before the course to get them up to speed – they get so much more out of the the live live


PECM Issue 33

course. During the course, in addition to seeing the animations and simulations, they receive repeated anonymous quizzes and exam standard “worked examples” examples” to ensure that everyone understands what they need need to to know. No student is left behind! And that’s the real difference. Mobius students understand the machine, the failure modes, the root causes, the vibration patterns and analysis techniques, and the analyzer; they are not just forced to remember. Since just 2005, we have trained over 24,000 people from 174 countries, in over 20 languages, according to the ISO 18436 standards. The certification is accredited to ISO 17024. There is no higher standard. So please visit or e-mail to to learn learn where where the the next next course course will will held. held. You You may may like like to to Google Google the the Mobius Mobius Institute Institute YouTube YouTube channel channel to to see see some some of of our our training training techniques techniques in in action. action.




The call for ‘lightweighting’ has led to significant advancements in how products are designed and constructed. Technology gains have resulted in new and exciting possibilities, but they have also created a unique set of joint design problems.

is made possible by the interaction of the mandrel and mandrel sleeve during the installation process. The presence of the mandrel accounts for a 60-80% increase in load-carrying ability in shear and tensile over conventional non-structural blind fasteners.

Our lessons learned from fastening traditional materials such as steel, do not translate to the ‘new’ composite materials, GRP or aluminium joints. Fortunately, proven technologies already exist to replace and even improve upon, now incompatible practices. Huck® structural blind fasteners have been used in many critical joint applications for decades, including widespread usage in aerospace, proving their reliability. The availability of carbon steel, aluminium, and stainlesssteel variations make Huck structural blind fasteners a viable option for joining a multitude of materials.

The Huck Penta-Lok has been specifically designed to work with celled / honeycomb plastic panels and multi-composite board. It’s wide blind-side footprint is well suited for use within thin materials and delicate composites. Penta-Lok’s uniquely engineered peel system installs with ease into shallow panels and its positive pin retention and domed head make it an ideal partner for commercial vehicle load restraint.

Structural blind fasteners offer similar benefits to those of non-structural blind fasteners, while also providing a distinct advantage: quantifiable and predictable shear and tensile strength. Structural blind fasteners such as, the Huck Magna-Lok® and Huck-Lok® retain their mandrel after installation. This retention of the mandrel

Industry is under continued pressure to do more with less: less weight, less cost, and less time. Understanding how different joining technologies function from the perspective of weight, cost, productivity, and reliability is crucial. While adhesives and welding are often the joining technologies of choice when trying to address weight concerns, structural blind fasteners should also be given strong consideration as they create effective, reliable, tight joints between various materials.

A wide selection of fastener options offers unique characteristics and performance. There is a solution available for each application. Email: Tel: +44(0)1159324939 (new website coming soon!)

manufacture a range of swivels joints. Swivel Joints allow fluids to be transferred FLUID HANDLING across rotating interfaces, without leakage.


Simple single flow units are used in many applications including MAGNETROL loading arms, articulated pipework and hose reelers. THE ELUSIVE SEARCH FOR NON-CONTACT Some applications require articulated pipe work or RADAR NIRVANA hoses to allow fluids; such When it comes to measurement, the as Hydraulic Power, Air ultimate goal for operators in the process industries is to find a trouble-free, loop(pneumatic) control lines, or powered level transmitter that can be mounted, wired and forgotten. mixed process fluids to be As instrument shops’ staffing has been used on moving machinery. whittled back to a minimum, it has become the goal of many manufacturers to meet that challenging need for “plug and play” devices.

So, how close have we gotten to applying two wires and walking away? This blog post explores the search for non-contact radar nirvana and how radar technology has evolved over the years. A History of Radar Advancements In the late 1990s and early 2000s, low-cost, loop-powered radar burst onto the scene. It was enthusiastically applied due to its ability to work even in the changing conditions that plagued the most popular technologies of the time. No longer would changing specific gravity ruin the accuracy of DP cells or displacers, or changing dielectric spoil the performance of RF capacitance devices, or vapor space changes affect the propagation consistency of ultrasonics. In short, a new age was upon us. Radar had already evolved into two variations: Non-contact/through-air (antenna-based) and contact/guided wave (probe-based). In a perfect world all transmitters would be non-contact so they would not have to contend with contacting the dirty, coatingprone, turbulent liquids that can wreak havoc with performance and mechanical integrity. However, since guided wave radar (GWR) employs a metallic probe, a highly efficient electrical path is provided to propagate the signal. This allows for extremely strong radar reflections from the liquid surface, thus providing excellent performance in difficult conditions. A Love-Hate Relationship Non-contact radar (NCR) slowly became the technology many people love to hate. Theoretically, NCR can be so effective it should be everyone’s first choice.


PECM Issue 33

The strong bearing area, of both ball bea rollers, is complimented with a choice of for maximum application compatibility. O 30 years Rotaflow have provided design many processing sectors.

Swivel joints will allow the movement on drum or remove the damaging effect of t We manufacture in both carbon steel and steel with “specials” in any It is small and easy to install. This means How Circular Polarization Helpsgrade of meta that measurement in tall tanks does cation not specifi - rangeenergy of sizes from ¼” to Electromagnetic can be launched necessitate a long, expensive and unwieldy probe like GWR, and the device sits up high in the tank, away from the tank contents.

However, the vagary of launching an electromagnetic signal into space and waiting for its return is fraught with potential complications: false reflections from objects in the vessel, severe turbulence that can scatter the signal and foam that can absorb it are just some of the issues that exist to render NCR ineffective. Users reported challenges getting these devices ideally configured, which discouraged others from using them.


The Goldilocks Dilemma

using linear or circular polarization.

Linear polarization has a constant E-field and needs adjusting to avoid sidewall reflections.

Tel: +44(0)1663 7350 Email: sales@rotaflow.

To remove these launcher adjustments, the new Pulsar® Model R86 non-contact radar transmitter from Magnetrol® employs circular polarization which has a rotating E-field. In this way, no antenna adjustment is necessary during commissioning, getting the user closer to the “plug and play” goal.

When configured properly, the Model R86 can be everyone’s go-to transmitter. Having said that, no transmitter ever made is totally trouble-free.

PECM Issue 24

Two of the keys to the effective use of NCR are correct installation and proper configuration. Installation includes avoiding sidewall and false target reflections.

But if problems occur, MAGNETROL should have the ability to diagnose them quickly and bring the device back on line as fast as possible.

Configuration is getting the gain (amplification) settings just right. This is the “Goldilocks dilemma”— it can’t be too hot or too cold—too hot (excessive gain) and the echo saturates (distorts), deteriorating accuracy; too cold (insufficient gain) and the weak signal is lost.

That means no more waiting for the troublefree, loop-powered level transmitter that can be mounted, wired and forgotten. Noncontact radar nirvana is finally here.

PECM117.indd 64

Optimal configuration is not an impossible task, but it is one that has eluded many good instrument personnel.

For more information about this new innovation in non-contact radar, visit

A variety of different materials like PTFE, FEP, PFA, PEEK an enable innovative products to be produced with excellent resistance and high thermal resistance. PTFE FLUID HANDLING FROM BOHLENDER


Labtex supplies leading laboratory products including HUBER liquid temperature control systems, DIEHM glass reaction systems to 100 litres, PREMEX and AMAR high pressure autoclaves, POPE wiped film or short path evaporators and distillation systems, Nutsche filter dryers, BOLA labware in PTFE and other technical plastics, Vacuubrand vacuum pumps, ASECOS storage solutions for hazardous materials to BS EN 14470-1 and SICCO desiccators.

Bohlender offers a vast range of finished and semi finished products in technical and fluoroplastics. A variety of different materials like PTFE, FEP, PFA, PEEK and others enable innovative products to be produced with excellent chemical resistance and high thermal resistance.

manufactures reaction vessels up to 6 litre capacity in PTFE or PFA. All parts exposed to the medium are either made completely of PTFE/PFA or jacketed like the thermometers.

Screw joints and ground joint components, tubing and co The BOLA catalogueto also includes allow an infinite number of combinations create soph a wealth of technical information on the materials used including systems of fluid transfer using standard laboratory bot Screw joints and ground joint physical properties and chemical containers. components, tubing and resistance and the safe use and

arings and needle We also work with LLG Germany, the 3rd largest sealing materials lab supplies distributor in connectors allow an infinite care of fluoroplastic labware. and have a catalogue of 20,000 items from over 200 Over the Europe passed number of combinations to create Further advice on the pressure respected brands. For distillation sophisticated of strong or of tubing alkaline product systems of fluidacidsresistance and the solutions within transfer using standard laboratory correct choice for pressure or

manufactures reaction vessels up to 6 applications litre capacity in PTFE bottles and containers. vacuum make the catalogue a useful reference. All parts exposed to the medium are either made comp For distillation of strong acids or alkaline products BOLA PTFE/PFA or jacketed like the thermometers.

n a slowly rotating twisting on hoses. d 316 stainless al to suit customer 36” nominal bore.

The BOLA catalogue also includes a wealth of technical info on the materials used including physical and It offers greatproperties advantages ... always an to the Contractor and resistance and the safe use and care of fluoroplastic labwa client alike – economy –


intelligent A method for working no inconvenience or long solution shut downs. of NO tubing TAP – is and th Further advice on the pressure on pressurised pipes resistance

quick – clean - positive. choice for pressure or vacuum applications Work is confinedmake to where the cat it is required. useful reference. eo d i Traditionally, modifications to ev pipe systems or repairs to h teh c leaking pipes or valves cause od t c COMPRESSION FITTINGS major inconvenience or high Wscaan the

003 .com m

cost. Often these works involve draining down whole buildings and lengthy refill with attendant venting & de-aeration. Often the process can take many days to complete and re-commission.

ORIGINAL RANGE Sizes 15 -100mm

NO TAP engineering goes to the heart of the problem on pressurised pipe-work by being effective in the right spot. It eliminates drain downs, refilling and venting. It accomplishes your solution in an interval of time that other methods fail to achieve.

QUICK RANGE Sizes 15 -50mm

LEAK SEALING CLAMP Sizes 10 -100mm


DZR Brass



For detailed information contact our sales department: C. A. Baldwin & Co. Ltd., Valan House, 146-154 Wells Way, Camberwell, London SE5 7SY Telephone: 020 7703 2138 Fax: 020 7701 8436

DZR Brass

Further information contact our sales dept: C. A. Baldwin & Co, Valan House, 146-154 Wells Way, Camberwell, London SE5 7SY 020 7703 2138 Issue 33 PECM

PECM Quarter page, CABCO.indd 1

10/03/2016 10:38




ECS ENGINEERING APPOINTS FINANCE AND OPERATIONS DIRECTORS Shelley Ward has been promoted to the position of Finance Director

Jamie Wesley has been promoted to the position of Operations Director

About ECS Engineering Services ECS Engineering Services has over 20 years experience in delivering high quality, reliable and cost effective engineering solutions, specialising in bespoke design and construction of water, energy and environmental processing and management projects. In conjunction with key supply partners, ECS has the expertise and capacity to design and install a wide range of water control engineering projects. With in-house fabrication services, which have CE Marking approval to EXC3, well equipped and highly skilled engineers can also complete structural steelwork, bespoke fabrication work and access metalwork to the highest standard.

ECS has grown significantly since its move to larger premises in Sutton in Ashfield, Nottinghamshire where the steel fabrication and engineering services company has its own 50,000sqft fabrication facility, steel stock yard and design offices. Recent contracts include applications as varied as structural steelwork and training rooms for nuclear power stations to framework contracts and major flood defence projects for the Environment Agency. The board now includes Bob Nix as Chairman, Gary Cormack as MD, Clark Williamson as Contracts Director, John Cotterill as Production Director, Jamie Wesley as Operations Director and Shelley Ward as Finance Director.


PECM Issue 33

Two important roles were confirmed recently at ECS Engineering Services Ltd. where Jamie Wesley has been promoted to the position of Operations Director and Shelley Ward to Finance Director. Both are internal promotions and were announced to the company by Managing Director, Gary Cormack. ‘Both Jamie and Shelley have shown themselves to be ideal candidates for board positions’ commented Gary Cormack, ‘I look forward to the positive contribution they will both make to the business as we move forwards’.

With a complete range of site services available, ECS offers a full turnkey project managed service for mechanical and electrical installations including managing civils contractors and supplying pipework, control and automation work to ensure that every installation is installed and commissioned to the highest standard. Existing clients include the majority of the UK Water Utility companies, Government Agencies and Internal Drainage Boards.

When you think about level measurement all day, amazing things happen. Introducing the Pulsar® R86 from Magnetrol.® At MAGNETROL, we’re obsessed with level measurement because we know how important it is to your operations and your bottom line. And all of that level thinking has led to a smarter non-contact radar. The new Pulsar® R86 is the 26 GHz model that features smaller process connections, higher resolution, higher temperature ranges and an antenna that extends from 4 to 72 inches. And no other non-contact radar offers these advanced diagnostics: • Automatic waveform capture with intuitive “Help Text” • Setup and Echo Rejection Wizards • Tank Profile feature that “learns the tank” Now you can give your facility radar solutions for every level measurement need with the new Pulsar® R86 Non-contact Radar and the industry-leading Eclipse® 706 Guided Wave Radar.

Learn more at © 2018 Magnetrol International, Incorporated




Located in the picturesque Italian Alps, around 1 hour from Venice by car, is the head office and workshops of PLD Collettori, a provider of commutators for the electric motor sector. The business is one of two recent members to join the AEMT (The Association of Electrical and Mechanical Trades).

Background and Capability Luciano Pesavento and his brother Dino acquired the 80's formed Veneta Collettori company in 2002 along with their workshop assets and equipment based in Valdastico, Northern Italy. Placing their initials PLD before the company name to form the company of today. Luciano is the mechanical engineer of the two brothers. His strong points may not be English, however with many other English speakers in the company for the international market, this isn't a problem.


PECM Issue 33

His entrepreneurial spirit, and acute understanding of mechanical engineering, inspired by his love of classic cars, means the company is thriving. Dino compliments his brother's mechanical strengths as an electronic engineer and has the same passion for business. He now also manages his own carbon composites company called Carbonveneta, most likely inspired by working in their father's construction company. When they bought the company, PLD's customer base came purely from the Italian market. A major customer of theirs at the time was the manufacturer Ansaldo (now part of Nidec). The last 16 years has seen the brothers expand and invest wisely in innovation, engineering capabilities, and business (Nestech). The company now has major contracts with Trenitalia Transport group, and exports between 70-80% largely to the European market, as well as the Middle East and Turkey.

They supply a full range of traction and industrial commutators from 250/800mm right up to the more bespoke 2000mm. Their small size, but multinational philosophy means they can offer a personalised service to manufacturing companies looking to find solutions through prototypes, engineering companies looking for replacement commutators for old equipment, or any bespoke design. With over 30 years of niche experience, PLD can be a welcome partner to draw knowledge and know-how from. Their expertise covers the range of technologies in use, calculating dynamic stresses, material selection, equipment design, assembly methods, and stabilization. An internal design department works with 3D CAD drawings to accurately produce a virtual design, which, when finalised, is also used to develop the jigs required for forming the commutators with great accuracy.

Creating Commutators

PLD can work with you to understand the application of the equipment and come to a suitable work specification for the grade of materials to be used. In addition to this, material grades, and modern manufacturing methods mean that mechanical strengths in the commutator can be improved. This might be required if the machine is to operate at higher speeds than originally specified.

Variation in commutator designs, means the design and construction is a skilled task. Whether replacing a commutator like for like, or designing a bespoke dovetail, glass-banded, or steel shrunk design, their understanding of the manufacturing methods can help.

The way the commutator bars and mica insulations (segment packs) are mounted onto the steel hub defines the type of commutator, all their methods are designed to apply considerable counter force to hold the bars together despite the high speed centrifugal forces.

When replacing a commutator like for like, it helps PLD if you have the original manufacturer’s certificate, drawings and dimensions. If these are not available,

Dovetail or V-ring commutators are the most common method of mounting and are used in most applications. A V-shaped notch is cut in the front and back of the

Incidentally, these jigs are also manufactured in house, contributing to their philosophy for quick-responsemanufacturing. Combined with an inhouse copper drawing capability, means Luciano's team can produce high quality commutators in-house, without the unpredictability and lead times from external suppliers.

(Left to Right) Luciano and Dino Pesavento of PLD Collettori, Roberto Movio of Nestech.

Issue 33 PECM


commutator bars. A corresponding Vshaped ring, insulated with mica, holds the commutator together. When clamped, tension forms between the bars and rings, drawing the commutator bars inwards. When designing this mounting method, an experienced designer allows enough bar height to accommodate the v-notch without weakening the bars. A shallow V-notch, designed incorrectly, will allow bars to lift in operation, which will lead to a failure. Glass-banded commutators are lighter in weight and require less maintenance. The segment pack compression is retained on the exterior of the commutator by cured glass banding applied in grooves adjacent to the brush track. These banded commutators, which lack clamping, means they cannot be checked for tightness in the same way as the dovetail configuration. However, by tapping each segment and listening out for the ‘ring,’ ensures the bars have remained rigid. Steel shrink ring commutators are designed for extreme duty applications and can withstand rapid acceleration and high speeds. The technique for shrinking-on is more modern than that used for dovetailing.

The equipment is not usually repaired; which is why PLD Collettori do not produce them. Finally, before shipping the finished commutators, several quality checks are carried out resulting in an impressive 1.8 x 1000 production defect wastage. Checks include: testing of dimensions, insulation resistance with a dielectric or hipot test, commutator hardness (Brinnel Test), measuring resistance to mass, heat seasoning of the commutator through various operating cycles, and an over-speed centrifuge test.

PLD Collettori sits comfortably in a niche market, for which there is very little competition in Europe. Luciano takes great pride in the quality of the work they produce and hasn’t any concerns about the future of the DC Commutator sector. Although an aging technology, there is plenty of room for business in other countries. The repair industry is becoming a large revenue generator for the business now, so their joining the AEMT network comes at a strategic time. Luciano and Dino’s partnership with Roberto Movio and Nestech was formed after exhibiting at CWIEME in 2013. Roberto was representing a steel cutting company close to PLD Collettori’s booth.

Molded commutators are typically smaller, less expensive, for high series production.

After getting to know one another better, they realised there was a clear synergy in their expertise and networks.

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Where the expanding companies go in the future, is too early to say, but for now the synergies and co-operation between these two companies is working very well. For enquiries, contact Dino or Roberto on +39 0445 745097 or on email by Their website can be found at

Next for PLD Collettori

The copper alloy body, which is held together by glass banding, is shrunk into an insulated steel body to give a single compact piece. This can reach high rotational speeds, even for very long commutators.


To support Roberto in the startup of Nestech, has meant PLD can reduce their overheads by sharing equipment, and improve parts of their own steel lamination production.

About the AEMT The Association of Electrical and Mechanical Trades (AEMT) was founded in 1945. It is an International Association representing leading companies in the electrical and mechanical service and repair industry. Members manufacture, distribute, install, service, maintain, and repair, electric motors, drives, pumps, fans, gearboxes, generators, transformers, switchgear, and ancillary equipment. In addition to motor and pump service facilities, most members operate mechanical engineering workshops for metal fabrication and the repair and refurbishment of worn components.



SAVING WITH MORE PERFORMANCE Richard Chambers is internationally recognised for his products, which are either unique or the best in the world, covering most areas in industry and transport, and also private areas..For friction reduction, SX6000 is the only product in the world with high density PTFE, which, added to any oil system, produces a coating on the friction surfaces with 0.02 coefficient of friction. (Next best 0.04). Cost reduction comes from the reduced friction, and wear reduction is certified to be up to 88%, on the road and in


PECM Issue 33

the works. In vehicle engines an oil-saving of 50% is also normal. Fault finding, from just starting, allows quick correction rather than waiting until a breakdown, also saves loss in production time. Leaks of compressed air or explosive gases can be found at 3 times the distance of the next-best fault finder, or with an accessory up to nearly 100 metres. The Ultrasonic SPY is the standard in many big plants in all industries.

Optimising electricity consumption in electric motors with the Powerboss is unique in the world, with several other programmable features, such as soft start and stop, which remove shock-loading, and overload and underload sensing. By air compressors at least 16% is always saved, and with SX-6000 added to their oil it goes up to over 20%. In some other applications even over 50% has been achieved.

When polymer oil seals start to lose their plasticisers, a “proper repair” with loss of production time to replace the seal is not required. Simply add LecWec, even possible while the machine is still running. Reports from users of over 15 years ago confirm that as long as the oil with LecWec is still in the machine, the seals remain cured. Compare the costs! If a power-steering leaks, “normally” it has to be replaced, with 4-figure costs. The necessary LecWec costs, for a private car, about $12. Intelligent lighting saves electricity and gives, for whatever is being done, ideal lighting. LED lights are optimal for lowering the power cost, and with the new and uniquely programmable sensor, quick group-changes ensure constant good working conditions, from precision work to warehousing. And replacement of fluorescent lighting will save the cost well within a year, and the lighting will hold for over 50,000 hours. Chambers warns, that there are several others who claim big savings, but who have no proof of such. For instance, frequency adjusters are claimed to be capable of serving if also fitted to motors which are not required to vary their speed. Lies and bribery. Demand scientifically solid evidence, on paper, and submit it to experts.




REMBE is continually expanding its portfolio of products and services. The latest addition to its consulting and engineering services is currently REMBE CAE. Until recently any customers who needed strength certificates, tightness analyses or temperature profiles, had to get these separately from engineering firms. This is now no longer necessary. REMBE is the first company of its kind to offer CAE services, so that each customer receives not only high-quality products but also comprehensive solutions and therefore


PECM Issue 33

genuine added value: lower costs and specialist calculations of explosion safety and pressure relief as a guarantee for highly dependable results. “We’ve been more than product suppliers for a long time now. Our specialists are continually on the customers’ premises, viewing their systems and developing specially tailored, cost-effective safety systems, partly also with the help of our CAE tools,” says Stefan Penno, Managing Director of REMBE GmbH Safety + Control. “Originally CAE was used entirely for inhouse purposes. However, we had such

positive feedback from so many customers that we decided to intensify this service.” So far customers have mainly requested strength calculations and tightness certificates. But REMBE’s CAE professionals are already working on a wide range of further options. T: +49 2961 7405-0 F: +49 2961 50714

Intelligent systems for process optimisation StockSAVER

A retrofit solution for FIFO flow racks to monitor stock movements and launch replenishment orders automatically - Kanban without cards.


Machine and workstation data collection and monitoring system - reduce downtime, get lean.


Call-for-action system for logistics operations identifies bottlenecks and gets things moving again quickly.

Made in Germany

WERMA (UK) Ltd. email:

Shop online at: Issue 33 PECM





Almost any place of employment can present a potential threat to health and safety from airborne particulates and aerosols. It is important to note, however, that dust hazards are not necessarily visible to the human eye and that the finest particles can represent the greatest threat because of their ability to travel deepest into the lungs. Effective monitoring is therefore key to the implementation of an effective risk management strategy. There are two major reasons for monitoring dust in the workplace; to enable air quality management, and for regulatory compliance. The immediate effects of dust can be irritation to eyes, headaches, fatigue, coughing and sneezing. As such, poor indoor air quality can lower employee performance and cause increased absenteeism through sickness. In addition, particulates are known to create long-term deleterious effects, contributing to serious illnesses. In combination with outdoor exposure (to pollution form vehicles for example), the Government has estimated that 29,000 premature deaths occur in the UK every year as a result of particle pollution. This means that, particularly in urban areas, natural ventilation may not necessarily improve indoor air quality. In order to evaluate workplace safety, monitoring data is compared with Workplace Exposure levels (WELs) which


PECM Issue 33

prescribe the maximum exposure level to a hazardous substance over a set period of time. Failure to comply with COSHH and WELs can result in financial penalties, prosecutions and civil claims. Indoor air quality is affected by both internal and external factors. Air pollution may arise from external sources such as neighbouring factories, building and development activities, or from vehicles – especially those with diesel engines. Internally, air quality is affected by working practices and business processes. For example, dust may arise from raw materials such as powders, or it may be produced by processes that generate particulates; including dust, mist, aerosols and smoke. In all cases, internal and external, it is important to identify both the source and the seriousness of the problem, so that appropriate and effective mitigation measures can be implemented. These might include, for example, ventilation, process dust prevention, the management of shift patterns, personal protection equipment (PPE) and alarm systems. •

For COSHH assessment, to help select the right controls

Where there is a serious risk to health from inhalation

To check that exposure limits are not exceeded

To check the performance of exposure controls

To help select the right respiratory protection equipment

To check exposure following a change in a process

To show any need for health surveillance; or

When an inspector issues an ‘Improvement Notice’ requiring monitoring

For more information on the latest instruments and on the range of parameters that can be measured, visit the Environmental, Health & Safety section of Focused on service excellence, Ashtead Technology provides fully integrated equipment solutions including rental equipment, equipment sales, calibration, repair and maintenance, offshore personnel and bespoke engineered solutions. Serving the subsea and onshore environmental monitoring and inspection sectors, Ashtead Technology provides global reach and local service from its facilities in Aberdeen, London, Houston and Singapore and via agents in Abu Dhabi, Perth and Stavanger.

T +49 2961 7405-0

Made in Germany

Your Specialist for



© REMBE | All rights reserved

Consulting. Engineering. Products. Service.

Gallbergweg 21 | 59929 Brilon, Germany F +49 2961 50714 |

Hydraulic power & control worldwide Industrial

Energy pFBK-065 a mid-sized, highpressure, dualdischarge pump.




SSr-05 a subsea regulator, without the ocsillation. The Oilgear Subsea Pressure Regulator is a robust, precision device that controls the pressure within a given circuit by serving as both a pressure reducer and as a pressure relief. The SSR is available in various sizes and control options (pilotoperated, mechanicallyset, and electricallycommandable).

pVG-048 an extremely responsive high-speed pump. The PVG is a variabledisplacement, axialpiston pump with fast control response. The PVG thrives on low viscosity fluids and is available in a variety of control and porting options. It is designed to be a highperformance solution for your demanding applications.



the flagship, highhorsepower pump.

a compact, highpressure pump.

The PVV line of Oilgear pumps represents the pinnacle of performance in a variabledisplacement, axialpiston pump. Pressure and flow demands continue to rise for our customers. The PVV is a pump that rises to the challenge.

The PFBA pump has proved itself successful for use with high water content and lowviscosity fluids. These axial piston pumps are used in a wide variety of applications, including oil and gas die casting and injection molding machines, high pressure test rigs, civil and marine projects, intensifier systems, extrusion presses, forging presses and high pressure forced lubrication systems for long turbines as well as metal forming machines.

Wide variety of applications: high pressure test rigs, civil and marine projects, intensifier systems, extrusion and forging pressure and other heavy duty metal forming machines.

introducing the pVV-180 and pVV-355 New additions to the ultra high performance line of PVV variable displacement pumps.

BEST UNDER PRESSURE The Oilgear Company provides robust hydraulic solutions for customers who prefer a partner not a vendor Our vision is to be the No.1 choice for hydraulic solutions in our target markets Oilgear engineered hydraulic solutions are amongst the most reliable and cost effective on the market. We drive the reduction of life cycle costs through innovation and engineering excellence We pioneer multi-fluid testing to promote the use of alternative hydraulic fluids As a partner we value customer satisfaction and being easy to work with Oilgear promote customer confidence through qualification

E: T: 0113 394 7300




TESTING & AFTERMARKET CAPABILITY • Hydrostatic Testing up to 1000 Bar • 6000 Bar intensifier rig

• Offshore Motion Compensation

• Pump dynamic performance testing (1000 Bar)

• Subsea Pumping Control • ROV Control

• Multifluid trials

• Blow-Out Prevention

• Rapid response emergency repair

• Hydraulic Press Control

• Routine service checks

• Electrical Amplifier Control

• Preventive maintenance • System performance diagnostics • Remote condition monitoring • Trouble shooting • Retrofit of new technology • System optimisation audits

• Sluice & Bridge Control • Transfer Barrier Control


• Finite Element Analysis • Computational Fluid Dynamics – System Simulation (SimulationX)

• Power On Demand life cycle cost reduction

• Variable displacement pumps • Fixed displacement pumps Hydraulic intensifiers • Bespoke hydraulic control systems • High pressure check valves • Pressure regulating valves • High pressure logic manifold valves • Subsea function valves • High speed relief valves • Screw-in cartridge valves

Visit our website to find out more about our products & solutions!





Twiflex, a global leader in innovative braking solutions, has launched a range of compact hydraulic brake packages, which are designed to meet the challenging braking requirements experienced in a wide variety of industrial applications. The standard brake packages, comprising Twiflex spring applied, hydraulically released caliper brakes and state-of-the-art compact hydraulic power units (Twiflex type LCS), are pre-assembled onto specially designed pedestals for ease of mounting and installation. The brake packages can be further customised to meet specific customers’ requirements. The high-specification hydraulic power unit features a fully-integrated hand pump for manual release of the brake in the event of power failure, pressure gauge and builtin terminal box to simplify the electrical connection. Key features of the Twiflex hydraulic brake packages include the compact dimensions,


PECM Issue 33

addressing applications with limited space available. A wide range of braking force ratings provide superior performance in applications as diverse as elevators, gantry cranes, winches, amusement rides, conveyors, metal processing lines and ski lifts. In addition, the integrated nature of the Twiflex solution ensures component compatibility and optimised performance, while minimising the installation time and maintenance burden. Three different spring applied, hydraulically released brake models are available within the standard Twiflex brake packages. These have nominal braking force ratings ranging from 6.8 kN to 119 kN. Twiflex, part of Altra Industrial Motion Corporation, specialises in the design, manufacture and supply of advanced braking technologies to deliver engineered solutions that meet the individual demands of original equipment manufacturers and end users alike.

About Twiflex Ltd Twiflex Limited, with headquarters in Twickenham, England, specialises in the design, manufacture and supply of Advanced Braking Technology for industrial applications. With extensive in-house facilities, Twiflex enjoys a global reputation for quality. Founded in 1946, Twiflex has produced more than half a million brake units, frequently for safety critical duty, for applications around the world. From textile machines in the north of England to the world’s deepest mine shaft in South Africa, Twiflex brakes are specified by engineers and system designers in every type of industry.



USE OF SUPERCORR A FOR MAINTENANCE OF ELECTRICAL CONNECTIONS ON GAS TURBINES IMPROVES PERFORMANCE BY REDUCING CORROSION FRETTING LP Gas Turbines are used throughout the world by extraction industries and manufacturing plants in remote and hostile locations for essential power production. Dusty and wet environments in deserts, mines, grinding mills, pulp and paper mills and on land or sea drilling rigs for gas and oil production. Turbines powering aircraft services while stationary connect and disconnect many times a day in extreme conditions. These applications and locations test connector sealing continuously allowing dust or water to penetrate. This with the flexing of the connecting cables allows sufficient movement between the metal surfaces of the connecting pins to produce fretting corrosion which reduces, interrupts or produces failures in supply. Regular maintenance of electrical connectors is essential to be certain of uninterrupted supply. SuperCORR A is an aerosol lubricant containing corrosion preventive compounds, and, as is the case with all lubricants, they can be worn off over time. A manufacturer of connectors tested SuperCORR A to see what the "life" of the lubricant was in a "rub test". The typical test is 20,000 cycles, i.e. unplug, plug in is one cycle. The test results demonstrated that after 20,000 cycles there were no failures. It was decided to take it one more step and run the same tests for 200,000 cycles. The results again showed no indications of galling or scoring on the connectors at all. The connector looked and tested as good as new. This test was run under clean conditions in a laboratory but demonstrates the effectiveness of the protective lubricant in SuperCORR A. As it meets Mil-DLT-87177B specifications it is used by the U.S. Air Force to protect the intricate workings of the F-16 and F-15 fighter jets and by the U.S. Navy on the P 3 Orion electronic surveillance aircraft. Savings for the U.S. government is estimated at $50 million per year.

Commercial Aviation aircraft manufacturers recommend it for avionics and electrical switches and connectors and close mechanical application, especially where flights are in salt fog or high humidity. Containing extremely long-lasting, proprietary anti-corrosive inhibitors SuperCORR A provides a superior lubrication coefficient and protects components against moisture, wear, general and fretting corrosion, surface static electricity, corona, and other electro migration problems. The super thin non-flammable lubricant film is only 7 microns (0.0007 inch) thick and is formulated without sulphates, chlorides or halogens to meet the RoHS directive. It is unexcelled in preventing deterioration and contamination on all surfaces of electronic equipment. Very fast drying environmentally acceptable solvents are used as carriers and propellants which will not affect most plastics, substrates, metals or other materials used in connector manufacture.

The aerosols are supplied with probes which allow access to pins and connector tubes where the low surface tension repels water, dirt dust and metal particles from blind holes and surfaces to produce thoroughly clean holes and surfaces before a second application applies the lubricant film. Reconnection to the supply with cleaned sections of the connector ensures reliable operation even in the most testing of environments. This easy maintenance from one can of SuperCORR A allows this essential task to be carried out in any conditions quickly, easily and securely.

For more information please visit:



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 0044(1527)520580


PECM Issue 33

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


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 004(0)1527520580

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!



MACHINE LEARNING IS STREAMLINING PREDICTIVE MAINTENANCE Over the past five years, the industrial sector has begun to see the value in digitalisation and has invested more in adopting it. With this has come a cultural shift from reactive equipment maintenance to proactive maintenance that pre-empts problems. Here, Sean Robinson, service leader at industrial analytics platform supplier Novotek UK & Ireland, explains how plant managers can make proactive maintenance even more effective with machine learning. In 2006, UK mathematician Clive Humby claimed that “data is the new oil”. Whether you’re a food processing company or an automotive manufacturer, data from production processes is the cornerstone of better efficiency, effectiveness and overall performance. Plant managers that are familiar with the industrial internet of things (IIoT) will know that one of the concept’s biggest selling points has been the insight it can provide into equipment performance and process effectiveness, which in turn creates benefits for the company’s bottomline. This has changed the culture of maintenance in plants that have started adopting IIoT technology. Rather than responding to a breakage or conducting planned maintenance based on expected equipment lifespan, engineers can make informed decisions about when to maintain systems based on the equipment’s condition. Minimising unplanned downtime has obvious benefits, but it’s the reduction in scheduled downtime that adds significant value in terms of increased overall throughput for no new capital outlay. However, achieving this is challenging due to the volume of data and subsequent analysis that is required to confidently change maintenance schedules. This is where an opportunity arises for machine learning in industrial maintenance. With machine learning, algorithms can be trained to identify correlating factors in data to not only flag up a problem but also the root cause of it. It sounds straightforward in principle, but the number of potential things to consider can be too high for a human to work through effectively. Within a single machine, there can be dozens of sensors or other health signals.


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To get a clear picture of all the things that affect reliability, that data should be evaluated alongside things like maintenance records and a history of what the machine was running. Even ambient conditions and crew data can give clues as to what issues can crop up. The only effective way to navigate the abundance of variables is with an IoT platform with machine learning, such as GE Digital’s Predix platform and Asset Performance Management (APM) suite. Connecting an IoT-enabled machine to the platform allows Predix’s machine learning algorithms to analyse it with the APM’s combination of standard measures and advanced analytics. This allows maintenance staff to not only spot when a machine needs maintenance, but also why. For example, a semiconductor manufacturer might find that it rejects ten per cent of its output due to faults in the manufacturing process. Although all the machines may be IoT-connected, there is too much data for an engineer to reasonably analyse. With Predix’s machine learning algorithms, the APM could, for example, identify that a machine has elevated vibration levels, which is damaging the semiconductors.

The algorithms can then assess this against historic data to spot patterns in how often this occurs, identify the performance signs that precede it and — if integrated into a management system — send alerts to engineers as the machine requires maintenance. This makes it possible for the machine to receive maintenance only when its conditions indicate it should, changing from preventative to condition-based predictive maintenance. In effect, machine learning allows maintenance data analysis to become a more automated process. In fact, there are certain industrial applications where the algorithms could be permitted to directly reconfigure a machine with the right settings. And as machine algorithms learn, this will become an increasingly viable way of improving efficiency. Whether you believe data is the new oil or not, it’s indisputable that it’s a valuable resource that fuels overall operational improvement for plant managers and maintenance engineers. The key to achieving this is to use industrial analytics intelligently and effectively to strike oil in industrial maintenance.

WEBSTER TECHNOLOGIES As specialist engineering and design consultants, our family heritage began in the early 1960’s where we began designing, manufacturing and global distribution of mining equipment, being the first to use hydraulics for cutting. The Webster Roadheader quickly became a well- known and respected brand and product range, still used in quarrying and mining applications today. Being the original inventors, we remain famous for The Rockwheel, now a proven and recognised cutting equipment attachment range, utilised in many industries and applications across the globe, since it was first introduced over 25 years ago.


Strategic Partners, Rokla GmbH. This collaboration has brought together a winning combination of creative technical design capability, quality manufacturing and sales and service focus, resulting in impressive global sales of the Rockwheel range of attachments. This successful collaboration allows Webster to continue to concentrate and focus on what we do best, the continued development and design of a range of new and exciting products, addressing Industry challenges, and focussing on the growth of the UK’s largest Rockwheel hire fleet and range of complimentary bespoke and Kennametal consumables.

Our International presence has continued to grow, when in 2013, we were delighted to licence the Magazine AdvertNEW.pdf 1 29/06/2018 09:07 manufacture, global sales and distribution of the Rockwheel to

Boasting the largest rental fleet of Rockwheels in the UK we are proud to offer our own designed rotary cutters in a range of sizes to fit excavators up to 125 tonnes. Powerful , robust and accurate , Rockwheels are effective in a wide range of applications including Trenching, Profiling, demolition and lots more. Excavated material can be recycled offering even more value. Low vibration and low noise operation means Rockwheels are an ideal choice for working in urban areas and wherever there are environmental constraints. WHY A HAMMER? WHEN A ROCKWHEEL IS MORE EFFECTIVE! Protected Motor // Valve Technology protects the hydraulic motor. Only Two Hydraulic Lines // No Drain Line Required - Works on hammer circuit. Transmission Ratio // Gearbox Units for Maximum Torque. Heavy-Duty Design // For The Toughest Job Sites. Most Experience on the Market // Invented and Engineered by Webster Technologies who have a history of design for the Mining Industry from 1960. // // 0114 2488 262

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MSE Hiller have recently installed several solids liquid separation units into the food industry many at household names such as Branston’s, Burts, Diageo, Heinz, Pepsico, Quaker Oats, Kellogg’s, Kettle, Walkers, 4Ufreshproduce etc The Hiller Decapress units are able to process high flowrates from a small footprint producing a high dry solids cake and a cleaned effluent which is easy to dispose of. Following a competitive tender for their production facility at Trafford park Manchester, Kellogg’s installed a DP37422VABD Hiller Decapress unit to process upto 14 m3/hr of water treatment sludge from a combination of DAF and biological processes. The machine which operates without polymer addition is able to achieve a dry solids cake of around 20 - 22% ds. Burts chips installed a DP37-422VABD Hiller Decapress unit to process up to 10 m3/hr of combined plant waste water. The machine which operates without polymer addition is able to achieve a dry solids cake of around 30 - 40 % ds reducing effluent disposal costs at their Plymouth site. Starch is notoriously high in BOD and it’s removal from effluent means that it can significantly save on effluent disposal costs vis the mogden formula as well as providing a saleable product.


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Potato starch solids recovery in the crisp Industry are typically a crumbly powdery white solids discharged at 60 – 70 % dry solids and Hiller have installed machines Worldwide in this sector including China, Egypt, Pakistan, Poland, Thailand, Turkey, USA… Meanwhile on potato chip processing lines and potato processing plants peel waste can be recovered and dewatered to a stackable transportable mass at 22 - 30% ds. Soil waters muds sands and silts can be dewatered to 45 – 60% ds. New developments for the food sector include the Three phase DecaOil machines are installed where Oil, Water and solids need to be recovered in a single process stage, often at elevated temperatures. Olive oils, fish oils and mineral oils are just three examples of this. Finally juices such as Apple, Beetroot, Carrott, Elderflower, Grape, Ginger, Garlic, Orange etc are processed on Hillertwo phase Decafood machines which produce high quality food grade products. With enclosed, highly automated, CIP systems in food grade designs and capacities ranging from 0.2 to 120 m3/hr the Hiller DecaPress, DecaFood and DecaOil centrifuges are certainly starting to rise and shine in the food processing industry sector.

T 01246 861166

Saving with more performance 5 technologies, all the best, or the only one in the world, have been recognised as the strongest in the world to reduce costs and emissions. 1. Friction reduction, 2. power consumption of electric motors, programmable, 3. locating faults (just starting defects, leaks, explosion risks and many more), 4. durable cures for oil leaks without loss of production time, and 5. intelligent lighting which saves its cost inside one year while providing fine programming for relevant lighting conditions. All five are relevant for almost all areas, so visit the home-page. to confirm this for your area, and send your questions to

High‐end camera series ImageIR® from InfraTec with new high‐speed mode for higher frame rates and increased thermal resolution at the same time InfraTec offers an entirely new level of flexibility for its high‐end camera series ImageIR®. In standard mode, the familiar frame rates for full frame, half frame and sub‐frame are available with full spatial resolution. In high‐ speed mode, images can be taken with the identical FOV – while the frame rates rises more than three times the previous value and the thermal resolution increases at the same time. If users want to depict the smallest geometrical details, they use the native number of pixels of the camera detector of up to (1,920 x 1,536) IR pixels.‐ camera/imageir‐9400/

TGF600 Thermal Mass Flow Meters for Syngas

New UV-light meter is compact, versatile and easy to use

Syngas or ‘synthesis gas’ is a combination of hydrogen, carbon monoxide, small quantities of carbon dioxide and other trace gases. Syngas is the result of gasification of various carbon-containing fuels to produce a gaseous product with heating value. This is what we know as Syngas.

Using the clear and well-organised display, measured results can be read at a glance. This new generation design is compact and hence extremely handy on the shop floor. Another user-friendly feature is the integrated USB port which enables the upload of the UV-Meter data easily to a PC or notebook, and recharges the lithium batteries which have a very long service life.

Thermal mass flow meters are the most suitable flow meters for Syngas. Comate TGF600 flow meters are being fitted to environmentally sound Syngas engines manufactured in the UK. They generate substantially less noise and lower emissions than equivalent diesel engines. As a result, creating clean, ondemand electricity. TGF600 flow meters accurately measure the consumption of Syngas by the generators. Contact or visit

The UV-Meter has a wide range of interchangeable sensors covering wavelengths from 230 nm to 550 nm – UVA, UVB, UVC and VIS which makes it suitable for different manufacturing processes. Its compact sensors are only 14mm high to fit into small spaces and its two channel measuring means that different wavelength ranges can be recorded at the same time. The unit also has automatic sensor recognition For further information please contact us at

Bell Flow Systems now offering the New Dynasonics TFX-500w Ultrasonic Clamp-on Flow Meter. Providing an economical solution for measuring water flow bi-directionally. This new model is easy to install - thanks to its clamp-on design. This makes the TFX-500w ideal for existing projects. The TFX-500w is capable of measuring flow rate, velocity and water flow with precision and accuracy. A large and user friendly display screen completes the design. Thanks to its flexible range of sizing and temperature handling abilities, the TFX-500w is an extremely versatile flow meter. Typical examples include water systems, wastewater effluent, agricultural irrigation and industrial discharge. Contact us at Bell Flow Systems for more information on the Dynasonics TFX-500w Ultrasonic Clamp-On Flow Meter.

Heraeus Fast Reponse Infra-Red Heater Provide The Answer at Tarkett Four fast response, medium wave infra-red (IR) heating modules from Heraeus Noblelight are helping Tarkett Ltd to significantly reduce the danger of flooring product manufactured at their Maidstone factory being spoiled or damaged in the event of unanticipated power cut-out or unexpected stoppage of the production line. Tarkett Ltd is a world-leader in flooring, with 12,000 employees and 34 manufacturing sites globally. It provides integrated flooring solutions to architects, facility professionals, contractors, distributors, installers and end users. The basic flooring production process consists of building up thicknesses of pvc paste on a pvc backing layer in 2m wide sections. Tel: 0151 353 2710 Fax: 0151 353 2719

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Electromagnetic Flowmeter -All metal design-

M-Zert ISO 9001:2008 Registered Company

Stainless steel version

°F °C


Flow and temperature measurement

Monitoring function

Total and partial quantity counter

2 configurable outputs

Display operation also with gloves


Rotating colour display

Space saver 94

PECM Issue 33

KOBOLD Instruments Ltd 8/9 Brunts Business Centre, Samuel Brunts Way, Mansfield, Nottingham, NG18 2AH Tel: 01623 427701 Email:




If you are involved with condition monitoring and reliability improvement, you know there is a lot to learn, and there is so much at stake. As they say, “you are only as good as your last recommendation”. But how do you keep learning? Do you randomly ask google and keep your fingers crossed (that you find what you want and that it is accurate and up-to-date)? Well, now there is a much better way to stay ahead, and to contribute if you are willing to share. CBM CONNECT is a new website that is filled with videos, tips, articles, and mini-courses that covers the topics you need – well, assuming you are interested in the following technologies: Alignment & Balance, Condition Monitoring Management, Lubrication, Motor Testing, Oil Analysis & Wear Particle, Thermography, Ultrasound, and Vibration Analysis. If you are familiar with the Mobius Institute animated training, including the now famous “Nine Minutes of Knowledge” videos and popular webinars, then you

will love CBM Connect. But CBM Connect goes way beyond Mobius. CBM Connect has bought together practitioners, industry experts, and solution-provider technology savants who have all joined forces to make CBM Connect the center of the known CBM universe. CBM Connect is not like any other site. You can declare which topics interest you, and you won’t see content on the other topics. If you are tight for time you can watch twominute tips, five-minute facts, and nineminutes of knowledge videos. Or you can read articles, watch longer videos, or attend webinars. Whether you want to detect problems or prevent problems, you will refresh what you were taught, and expand your knowledge and skills at CBM Connect. Visit You can optionally register, without any charge, and be notified about topics that interest you, add content to your personal library, and take “learning paths” (like mini-courses), and more.

“Condition monitoring practitioners have a rewarding but challenging profession and they need a resource where they can learn and share. Rather than googling endlessly or being lost in a forum with a different focus, we are proud to offer CBM Connect,” said Jason Tranter, CEO and founder of Mobius Institute. “It’s engaging content is geared towards the specific needs of CBM practitioners, whether that be based on technology, application, depth of required knowledge, or preferred media format; CBM Connect offers a focused resource that recognizes their unique requirements.”

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The Tinytag range of data loggers includes rugged devices designed for monitoring in industrial, manufacturing, process and engineering applications.

A range of units is available to suit specific applications:

Compact, accurate and versatile, Tinytags help ensure that conditions can be measured, recorded, analysed and validated. Tinytag data loggers record:

• • • • • • •

Temperature Relative humidity Single and three phase power usage Carbon dioxide Low voltage Current Count inputs

• •

Standalone, network enabled or wireless devices Dual channel loggers to simultaneously monitor two parameters e.g. temperature and RH Rugged, waterproof and dustproof units Units with displays showing current readings as well as recording data Fully submersible, high temperature loggers Range of accompanying thermistor probes, PT1000 very low temperature probes, and PT100 very high temperature probes Voltage, current and count input loggers for connection to third party sensors for specialist applications

Loggers are set up, and recorded data displayed in the Tinytag Explorer software, an easy to use Windows program.

Results from separate logging runs can be combined for comparison and analysis, and data can be exported into popular desktop packages for use in reports and spreadsheets etc.

Tinytags are cost-effective with an established reputation for accuracy and reliability, and have been designed and manufactured in the UK by Gemini Data Loggers since 1992.

Tinytag Data Loggers:

The Tinytag Energy Logger is an easy to use, non-invasive device for monitoring power usage in high consumption facilities

Gemini Data Loggers (UK) Ltd Scientific House Terminus Road Chichester PO19 8UJ T: +44 (0)1243 813000

Tinytag Plus 2

Energy Logger

Rugged outdoor/industrial temperature/RH logger From £95 +VAT

Non-invasive single & three phase power monitoring Full kit £795 +VAT

Radio and LAN loggers

Tinytag Ultra 2

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

Manufactured in the UK

• Data downloaded to PC • Cost-effective Accompanying probes are available for monitoring extremes of temperature, and for awkward to reach areas such as pipework. Automatic data collection Bundles – 3 loggers/receiver/ software from £1000 +VAT

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



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


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power usage


Telephone: +44 (0)1243 813000 email:




Indoor temperature & RH From £69 +VAT









The VEGADIF 85 differential pressure transmitter offers a host of user benefits based around ease of use, productivity, safety and reliability. It makes set up and operation simpler – whether locally in the head via push buttons, magnetic pen or remote: as the first DP transmitter to feature Bluetooth encrypted technology, it can be set up from a safe, convenient location; using either Smartphone, Tablet or PC and/or via traditional HART Handheld. For safety related applications it features EIC 61508 SIL2/3 conformance for peace of mind. VEGADIF 85 has integrated independent static pressure measurement for enhanced accuracy and stability – ideal for flow applications. This static pressure measurement can be output as a second process variable for total system pressure. As part of the plics® system from VEGA, it shares common features with all other transmitters in the range; universal programmer, multiple housings, easy set up and a variety of communication options: 4-20mA (twin 4-20mA), HART, Profibus and Foundation Fieldbus. To complete a range of flexible

differential pressure solutions, it partners VEGABAR 80 series e-DP systems for complete versatility and capability for flow, level, density corrected level, pressure, density measurement, interface and many other applications. The VEGA pressure range is comprehensive, competitively priced, with a choice of measuring cells and certifications, with easier, faster installation, and a quick 3-day delivery for standard options with a 3 year warranty. For a live demo or trial, please contact VEGA. E-Mail: Web:


Titan Enterprises announces MetraFlow® - an exciting new addition to the company’s expanding ultrasonic flowmeter range. The new MetraFlow ultrasonic flowmeter from Titan Enterprises incorporates a chemically resistant Perfluoralkoxy Alkane (PFA) tube onto which are mounted high sensitivity ultrasonic sensors. There are no dead areas, changes in fluid direction or obstructions, just a tube. As a result - MetraFlow


Liquid flow measurement in Process industry applications can present varied and challenging requirements and Micronics has had 35 years of experience in providing cost-effective and reliable solutions for applications in various industries including Nuclear Power, Dairy, Food Processing and the Semi-conductor industry. There are many process liquid flows, which require a noninvasive measurement: to avoid contamination of the liquid, because of the corrosive nature of the liquid or to make ongoing servicing and maintenance easier, where this presents a challenge due to the location or critical nature of the process. In full pipe applications clamp-on, ultrasonic flow measurement is often the best solution and Micronics is the longest established UK manufacturer in this technology with a wide range of portable instrument and fixed measurement, metering products backed up by previous application experience and technical support.

can make non-intrusive flow measurements preserving the cleanliness of your process. Applications including drug production, electronic device creation, medical research and food manufacture, require that a flowmeter has no inclusions or dead areas as this can lead to contamination issues for the liquids used in these processes. For further information please visit

Micronics has a wide range of Process application experience including oils, paint and water solutions, acid, paper industry slurry and a wide range of both clean and dirty water applications for full, partial pipe and open channel flows. This includes products using Ultrasonic Doppler, Transit Time and the latest Microwave technology. However, we recognise that clamp-on is not the only solution and so in areas such as Waste Water monitoring and metering to challenge back to sewer allowances or comply with Effluent licence requirements we can supply a cost effective in-line solution using an advanced range of Microwave products. So if you need to measure or monitor process liquids, water or waste water flow in your industry we believe we have the solution.

Please call Micronics on +44 (0)1628 810456 or email: to discuss your requirements

Issue 33 PECM





Where does the humble thermocouple stand in the high-tech world of measurement and control? The funny thing is that the temperature instrumentation market is dominated by complex, sophisticated measurement and control systems which provide a great degree of versatility and accuracy but, in many applications rely on a simple thermocouple (base-metal type usually) as the temperature sensor. Surprising really since instrumentation is typically accurate to a fraction of a degree centigrade whereas a base-metal thermocouple has uncertainties of ±2oC before it even sees the process. Since measurement accuracy of the entire process is only as good as that of the sensor, why rely on something that, in principle, at least, has not significantly changed in nearly 200 years (Thomas Seebeck discovered the principle of the thermocouple in 1821). Why indeed especially when you are presented with a feeble output (typically 40µV/oC), a non-linear transfer characteristic and the need for automatic “cold-junction” compensation or some external ice reference; also, one of several types must be selected for each application, complete with a dedicated type of extension cable.


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The answer to these questions is a surprisingly simple one – nobody has yet been able to come up with anything better to cope with harsh environments and wide temperature ranges. The entire range of commonly used thermocouple types (J,K,T,E,N,R & S) span –200oC to 1800oC depending on their construction; they are generally rugged thanks to sheathing options and can operate in corrosive media; replaceable world-wide; reliable and, in Mineral Insulated form, flexible and versatile. All thermocouple types are supported by the majority of microprocessor based instruments; they do not require excitation since they are thermoelectric and can operate with reasonably long cable runs. There are, of course, many alternative types of temperature sensor on the market including resistance thermometers, thermistors, infra-red devices; all valuable in particular applications. However, none of these alternatives to the thermocouple can compete in terms of temperature range, versatility and cost-effectiveness. Labfacility has been manufacturing thermocouple and resistance thermometer assemblies for over 47 years.

Bognor Regis Tel: 01243 871280 Sheffield Tel: 01909 569446



RHEINTACHO INSTRUMENTS AND TACHOMETERS Rheintacho UK Ltd, a subsidiary of German Rheintacho Messtechnik GmbH, is located in Leeds and has over 300 years of combined history and experience coming from its time as Foundrometers Instrumentation, through the acquisition of Harding of Leeds and due to its close relationship to Germany and its products. Rheintacho UK is now the competence center in the companies group responsible for intrinsically safe applications and is continuously expanding its product portfolio for offerings to companies working in hazardous environments which need tachometers and stroboscopes for measurement, monitoring and control of speed and linear movement in operations and in maintenance of equipment. In production environments, the mechanical and electrical tachometers, such as eddy current tachometers provide reliable and easy display of speed and associated properties. These tachometers are always calibrated to suit our customers applications. Our handheld mechanical tachometers which require no batteries, are most suitable in maintenance operations by inspectors, service engineers and inspectors. They are often used in elevator, pump, motor and other areas where a reliable, portable and easy-to-use tachometer can facilitate maintenance. They are offered in both imperial and metric versions for speeds up to 50,000 rpm. Our eddy current tachometers which are very often also used as flowmeters, are connected to a moving component by a drive coupling. The movement is then transferred to the dial which can be specified to any application. We are also in the process of certifying the complete line of eddy current tachometers with and without a gearbox for intrinsically safe applications. We also offer a wide range of tacho generators for the accurate measurement of rotational speed of motors and engines. The signal which comes from the shaft to which the tacho generator is connected is transferred to a Rheintacho indicator. There is a wide range of alternatives depending on the voltage, current or pulse output. Typical applications are for the measurement of rotational speed of ship engines, turbines, rotors, rollers or conveyor belts. They need no external power supply which makes them attractive especially when on-board supply fails completely. The tacho generator continues to provide accurate readings.

For further information, quotes and consulting, please contact us at: Tel.: 0113 287 4411




Process water often has to be modified to meet the required quality standards, either as part of a manufacturing process or to prevent corrosion, microbiological build-up or scale formation. Monitoring a combination of pH, chlorine, reduction potential (ORP), temperature and conductivity is the first step in achieving the optimum process conditions. Combined with precision flow measurement and control circuits, the quality of process water can be achieved and documented.

Fixed ratio control requires the quality of both the raw water and the pure water to remain consistent. To achieve this, flowmeters are used on both lines and a control valve is used to deliver the correct ratio for the blended water. The alternative is to use a water quality monitor that is set up to measure a parameter, such as conductivity. This monitor is linked to the water supply valves via a control loop that regulates the blending proportionally and can therefore compensate for variations in supply quality.

From cooling towers to craft breweries, process water has a wide variety of uses and each application has different demands. Water quality is often controlled using a blending process that combines two sources of water of known quality to produce the required process quality. This can be achieved either by ratio control or quality control procedures.

Designing and creating these control systems requires considerable expertise to ensure that they perform reliably and are properly integrated with the surrounding control infrastructure. Process control experts at BĂźrkert have created an extensive range of compatible flow control and quality measurement products that can be combined to deliver an optimised quality control system that can be scaled to suit any process.

Preventing corrosion and the deposition in cooling towers for example can be achieved through the careful blending of treated and raw water to create the right balance for make-up water used to maintain system levels. Water blending also has a significant effect on consumables such as beer, where the taste is affected by the water composition going into the fermentation process, so monitoring and maintaining a high-quality source of process water is essential.


PECM Issue 33

Systems can be designed around pneumatic or electrical valve actuation and in-line sensors, using either a stand-alone process controller such as those offered by BĂźrkert or using PLC control that is incorporated within the wider process environment. Smaller systems can be pre-assembled from standard products and bench-tested prior to installation, while larger, more complex designs can be individually designed and kitted to ensure smooth integration.

BĂźrkert Fluid Control Systems is one of the leading manufacturers of control and measuring systems for fluids and gases. The products have a wide variety of applications and are used by breweries and laboratories as well as in medical engineering and space technology. The company employs over 2,500 people and has a comprehensive network of branches in 36 countries world-wide. Tel: +44 (0)1285 648720 Web:

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Following a move to new premises with custom built service facilities, Ashtead Technology has extended its RAE / Honeywell servicing capabilities to help customers ensure the accuracy and reliability of their gas detection activities. RAE Systems products are used in more than 120 countries by many of the world's leading corporations and government agencies. As such, enormous numbers of people rely on these instruments in a wide range of personal and plant safety applications. However, Will Russell a Technician from Ashtead Technology, warns: “There is a danger that investment in monitoring equipment can create a false sense of security. All instruments require regular health and calibration checks to ensure that readings remain accurate, because incorrect data can mislead users into believing that conditions are safe, with potentially disastrous consequences. Instrument maintenance might not seem like a life and death issue – but if you think about it; it actually is.” The service and calibration of gas detection equipment requires specialist skills, equipment and gases, so it is vital for the operators of these instruments to implement appropriate procedures to ensure that they


PECM Issue 33

remain in optimal condition. Will Russell says: “Many Ashtead customers undertake routine calibration themselves and only return their instruments to us for service. However, the proportion of clients that prefer to rely on us for all of this work is constantly growing. This is because we have the equipment and skills required to undertake the work, and loan instruments available to rent with a rapid turnaround, so we are able to ensure that monitoring is not interrupted and safety is protected.” Ashtead Technology has invested heavily in its new dedicated service facility, which is fully equipped with all the necessary service and calibration tools, including specialist gases and Honeywell approved parts. The service team benefits from regular Honeywell training courses and the company is certified to ISO9001. In summary, gas is only potentially fatal when it is either not monitored, or monitored by equipment that has not been correctly calibrated and maintained. For more information on the range of parameters that can be measured, visit the Environmental, Health & Safety section of

Focused on service excellence, Ashtead Technology provides fully integrated equipment solutions including rental equipment, equipment sales, calibration, repair and maintenance, offshore personnel and bespoke engineered solutions. Serving the subsea and onshore environmental monitoring and inspection sectors, Ashtead Technology provides global reach and local service from its facilities in Aberdeen, London, Houston and Singapore and via agents in Abu Dhabi, Perth and Stavanger.

Industrial endoscopes for nondestructive testing Endoscopy has also become an indispensable tool in industry. There are few fields in which endoscopy cannot provide rapid, inexpensive and objective information about the interior condition of an object without the need for time-consuming disassembly or causing any damage to the object inspected. Industrial endoscopes from KARL STORZ are used in particular for safety checks and maintenance work in the aerospace and energy sectors as well as for quality assurance and materials testing in manufacturing. Further fields of application include the safety sector, research and development in automotive technology, the construction industry, expert appraisal, the foodstuff industry and many other fields of application.

LGG Charlesworth rebrands, reflecting the wider reach of its plastics operations


Malvern-based LGG Charlesworth, a brand that has been synonymous with the UK plastics industry for almost 100 years, is preparing for the future with a series of initiatives to take the company to the next level.

EBE Engineering, a leading developer and supplier of Venturi orifice steam traps, has launched ECOFLOW, a market-leading steam trap that incorporates the flange into the main casting. The EFK-F and EFG-F versions are both cast in one piece, using CF8 Stainless Steel, which provide the traps with consistent strength, resilience and dimensional accuracy.

From 1st June 2018, this precision plastics injection moulding specialist will become Talisman Plastics. A new logo, corporate branding and new website have been introduced to reflect the transformation and ambition of the company. Overseeing this transformation is Shaun Champion, appointed managing director on 1st May this year.

Tel: 01635 600424 Email:

Tel: 07761 674499 Email:

Climatic Packaging Solutions Protective Packaging Ltd is a specialist in Dried Product Protection and Corrosion Prevention, with over 30 years experience. They design, manufacture and supply climatic packaging solutions to suit their customer’s requirements. Aluminium Barrier Foils are a flexible barrier laminate, that protects atmospherically sensitive during storage and transportation due to its extremely low Water Vapour Transmission Rate (W.V.T.R) which as well as its barrier properties to oxygen ingress and other gases. Protective Packaging Ltd is an ISO accredited manufacturer that supply and export climatic packaging solutions globally to over 50 countries and have recently opened production facilities in Orlando, FL trading as 3D Barrier Bags Inc. For your bespoke climatic packaging solutions – Call 0161 973 2006 or visit

The new trap’s body comprises of a modular design to incorporate low and high flow in the same housing. Due to a unique and innovative Venturi concept, the new design extends the trap’s performance over variable condensate loads. Welding has been eliminated, resulting in a totally homogenous design that makes the trap physically stronger and safer.

HBM AND BRÜEL & KJÆR SOUND & VIBRATION TO MERGE HBM – a market leader in the field of test and measurement – is pleased to announce it will be merging its activities with BKSV (Brüel and Kær Sound and Vibration) from 1 January 2019. Both owned by UK based Spectris Plc, the new company will be named HBK (Hottinger, Brüel and Kjær). Both HBM and BKSV are global leaders in their respective disciplines and have complementary expertise across the measurement chain. By leveraging their respective strengths, the aim is to create a business with the capabilities, breadth and scale to deliver differentiated customer value, for example, in the domains of propulsion, durability, safety and noise, vibration and harshness. For further information, please contact HBM on +44 (0) 1525 304980 or via email: or visit the HBM website at

Gratnells Engineering continues to support customers by expanding engineering solutions Gratnells Engineering has been providing engineering solutions for nearly 130 years. Historically known as the leading name in school storage in over 68 countries of the world (and the producer of the iconic Gratnells Tray) Gratnells Engineering has developed into a multi-sector manufacturer capable of providing high-volume laser cutting, powder coating and bespoke metal solutions to a wide range of customers. The Harlow-based manufacturer specialises in short run, quick turnaround projects, giving customers shorter lead times, high precision and quality customer service. Powder Coating, Injection Moulding and Laser Cutting are just some of the areas where investment has been made this year, including a new Sprayline Plant machine, IM machine number 8 and a BLM LT Fiber tube cutting machine. For more information and the latest news on Gratnells Engineering, please visit


PECM Issue 33

Probably the Most Environmentally Friendly Double Skin Tank Lining System in The World Fuelvac® solvent free double skin lining system provides around the clock leak detection for above and below ground storage tanks of any size, utilising Class 1 vacuum pressure monitoring. The World’s only double skin liner that uses solvent free coatings throughout the system alongside non-hazardous materials. The system has been independently tested to conform to EN13160-7:2016 by TUV NORD and has completed all testing successfully. For more information please visit: Email: Tel No: 0191 543 7166

Denso Steelcoat™ Protects Newquay Private Suspension Bridge If your home is the beauty of an island, connected to the Cornish coast by a suspension bridge, you have few problems but one of the biggest is the corrosive marine atmosphere. When the owners of The Island in Newquay were planning maintenance work on their private footbridge they wanted to use a product which would give the steel cables long-lasting protection against the harsh coastal elements. Winn & Coales (Denso) Ltd were contacted to meet this challenge and advised the use of their Denso Steelcoat™ 100/400 system. Denso Steelcoat™ Systems provide a costeffective, long term solution to corrosion on exposed steel and can provide many years of maintenance free service life.

New WypAll* ForceMax industrial cloths – the best hire you’ll make With the launch of its new WypAll* ForceMax Industrial cloths, Kimberly-Clark Professional* is challenging manufacturing facilities to apply the same rigorous standards used in hiring employees to selecting wiping solutions. The ‘Who would you hire?’ programme demonstrates that selecting the right wiping solution in manufacturing environments is just like hiring an employee and therefore can positively impact KPI’s, improve productivity, increase operational efficiencies and reduce waste. Who would you hire? is introduced in 2018 for the launch of WypAll* ForceMax and pitches the WypAll* range of industrial cloths against traditional rags and laundered cloths used in plant and manufacturing settings.

WESTERMANS INTERNATIONAL – PROUD SPONSORS AT THIS YEAR’S WELDING WORLD AWARDS Westermans International Ltd. has once again been proud to play a key role in this year’s Welding World Awards held in April in Birmingham. The Leicester-based company, which has specialised in the sourcing and supply of refurbished welding equipment to customers both in the UK and worldwide for some 50 years, sponsored the Best Welding Machines Supplier category at this year’s event. It is a role which, says founder Peter Westerman, is a perfect match for the company’s business. Full details of Westermans International’s services can be found at

William Hughes meets new challenges for high performance spring in critical aerospace application William Hughes has been manufacturing precision, high specification springs for many years, and is well equipped to meet the exacting demands of the aerospace industry including its special requirements for materials, specifications, manufacturing tolerances, cleanliness and packaging. The application required a large spring which, as well as being manufactured in a specialist aerospace certified material - which has a high spring index making it difficult to form, the unusual specification called for one end of the spring to be fusion welded using stainless steel filler rod. For further details contact William Hughes Ltd, Station Road, STALBRIDGE, Dorset DT10 2RZ Tel:(01963) 363377 Fax:(01963) 363640 Email:

LEDsynergy Displays Ltd Electronic Message Display Systems are now a part of everyday life, from Information and Advertising Boards, Production Monitoring and Safety Displays to Transport Signs, Retail and Video Scoreboards. Modern technology and latest manufacturing capabilities have produced displays that are extremely cost conscious as well as being high quality. The LEDsynergy have been installing displays for more than 35 years and their LED Display Systems are probably the most advanced available and can convey vast amounts of information with high brightness LED characters in Full-colour, housed in standard or bespoke casings the displays can be simply controlled by many communications methods. LEDsynergy (Displays) Ltd Tel: 01264 303030

Issue 33 PECM


Electronic Components Market Germany (FBDi e.V.) in Million Euro 1,40

1.400 1.200 1.000

1,13 0,98




1,16 1,04



1,20 1,00






0,40 0,20

200 0




4Q/16 Billings

1Q/17 Bookings






Book-to-Bill-Ratio Source: FBDi e.V., June 2018

GridBeyond creates new jobs and plans for international expansion.

German Component Distribution Sector Defies Challenges

White paper explains a new toolmaking technology to cut lead-times

GridBeyond, formerly Endeco Technologies, will create close to forty new jobs over the next three years as a part of business growth and planned international expansion.

Despite component shortages, the German component distribution market (according to FBDi e.V.) posted further growth during the first quarter of 2018. For the period January to March 2018, the distribution companies organised under the Fachverband Bauelemente Distribution association reported sales of 978 million euros – up 7% compared with Q1/2017. Orders rose 8% to 1.09 billion euros. The order situation remains stable, the book-to-bill ratio of 1.11 (the ratio of orders received to units shipped and billed) remains in the “green” zone.

OGM, a specialist in plastic injection moulding, has published an in-depth white paper explaining how a new toolmaking technology can help companies half the lead time for mould tools.

GridBeyond, the creator of the world’s first hybrid battery & demand network, leading provider of demand side response services and energy optimisation technologies, is proud to announce its further dynamic growth forecast for the next three years. The company is predicting greater than 100% year to year revenue growth in 2018, having already seen a fivefold revenue increase over the period 2014-2017. GridBeyond’s award-winning client facing portal is also undergoing significant upgrades.

FBDi Chairman of the Board of Directors Georg Steinberger remarked: “The low growth rate for Q1/2018 is largely the result of delays to purchase orders and existing orders caused by the long delivery times affecting numerous components.”

In 1948, Southern Springs Ltd opened their doors for the first time by founding partners Jack Harman and Richard Fletcher-Jones, they quickly moved the business to a barn in Old Milton and Joseph (Joe) Williams joined the expanding spring manufacturer.

In 1989, and on the retirement of the two founder members, Tony Williams took over the running of the business as Chairman. It was at this point that the company widened their manufacturing capability to encompass tool making, the production of metal pressings and wire forms, the spring manufacturing business also embraced new CNC technology.

Joe and Richard continued to run the spring manufacturing business over the next 40 years.

A new board of Directors were appointed In 2015 with two long serving members of staff taking up senior roles within the company. Tim Page as Managing Director and Steve Blunt as Quality Director.

The spring manufacturing business thrived on being particularly well placed to design and manufacture specialist coiling machines for the production of products that could not be made on standard machines of that era.

Under their leadership, supported by the new board and 27 dedicated employees, the firm has invested heavily in state of the art highly complex computer controlled machine tools.

As the business expanded it became necessary to build a new and more modern factory in its current location in New Milton in 1964.

SSP has been taken to new heights, winning major long-term contracts ensuring secure employment and greater company profitability, far removed from its humble beginnings in the late 1940’s.


PECM Issue 33

Conventional toolmaking processes can entail a four-month wait between sign-off of a part design and the availability of production components.

SOUTHERN SPRINGS AND PRESSINGS CELEBRATE 70 SUCCESSFUL YEARS OF TRADING New Milton based spring manufacturer, Southern Springs and Pressings Ltd have celebrated their 70th anniversary of trading.

For products using plastic components, the design and manufacture of injection mould tooling can be a significant bottleneck on the journey from prototype to full market availability.


Tim Page, Managing Director said “We are delighted to celebrate 70 years of trading, the business has grown significantly since opening their doors in 1948. The last few years have seen some huge investment in the factory environment and purchasing of new machines, We are looking forward to developing the business further in 2018 and beyond”.

Visit to find out more.

COUNTDOWN BEGINS TO THE UK’S LEADING PROCESSING & PACKAGING MACHINERY EVENT The PPMA Show to celebrate its 30th anniversary at the NEC Birmingham 25-27 September 2018

ABB and Omron Electronics UK, creating an unrivalled platform to connect, engage and network with suppliers and industry peers.

Celebrating its 30th anniversary this year, the PPMA Show will return to the NEC Birmingham from 25-27 September 2018 to showcase the latest innovations in smart manufacturing, processing technology and packaging machinery, aimed to increase production line efficiencies and enhance business performance and profitability.

Commenting on the forthcoming show, Dr. Andrew Mint, Chief Executive Officer, PPMA Group of Associations said, “Our 30th anniversary show comes at a time when UK manufacturing is enjoying its longest period of expansion since 1968 and these positive signs will undoubtedly boost confidence throughout our sector.

New to the show this year will be the Enterprise Zone, which will offer visitors a focal point for learning, networking, discovery and live debate.

Against this future optimism, the PPMA Show 2018 looks set to be one of the biggest and best to date, where visitors can benefit from an unsurpassed skill set of experience, expertise and industry knowledge and witness the latest processing and packaging technologies in real-time demonstrations.”

Presenting the biggest and most comprehensive line-up of production technologies and solutions for the food and beverage, pharmaceutical, toiletries and FMCG sectors, visitors to the show will see 350 exhibitors representing 1,500 brands, all under one roof.


About the PPMA Show The PPMA Show is the UK’s leading production line event for processing and packaging machinery. Taking place at the NEC, Birmingham from 25-27 September 2018, the exhibition showcases the latest innovations in processing and packaging machinery and is attended by thousands of manufacturers of food, pharmaceuticals, toiletries and FMCG, contract packers and more. The PPMA Show and PPMA Group Industry Awards are organised by the Processing and Packaging Machinery Association (PPMA).

Leading players already confirmed include Schneider Electric, Ishida Europe, Bosch,

UNATTENDED PRODUCTION FOR RUTLAND Rutland Plastics, is a private company based in Oakham Rutland with a 66000 ft sq factory and a turnover in excess of £10 million, operating moulding machines ranging from 150 tonne to 1700 tonne. Looking to achieve unattended production on a Krauss Maffei KM150, Rutland Plastics selected UPM Conveyors to provide a turnkey solution requiring 8 belt conveyors to allow automatic product divert for QC inspection; ferrous/non-ferrous metal detection; product cooling; parts separation and box filling with a capacity of 8 full; 8 empty and 1 filling. Product divert is achieved with a small reversing conveyor located onto a swan neck conveyor in the well of the machine and at any stage in production an operator can energise to reverse and transfer a shot to an integral sample drawer for QC inspection.


Metal detection is based on UPM inserting a search coil under the inclined section of the Swan Neck in the well of the machine and on detecting a foreign body will energise an audible / visual alarm and stop the belt conveyor so an operator can check and remove the contamination. This does not affect the moulding machine cycle as product continues to be produced and accumulated on the conveyor until the operator has reset to start again. The central control is a PLC controlling all aspects of the system interfacing with the variable speed drives on each conveyor and connecting to the weigh scale. Rutland expressed their total satisfaction with the UPM project team who installed and commissioned the system which is operating 24/7 trouble free. Issue 33 PECM





Responding to the rapid need for food factories to use sustainable packaging materials, Ilapak UK has successfully adapted one of its vertical flow wrapping systems, the Vegatronic, to run a new compostable film. Following this breakthrough, Ilapak plan to modify its entire fleet of over 1200 vertical and horizontal systems and offer an upgrade option to existing customers wanting to switch to environmentally friendly substrates. From government through to consumers, the nation has waged a war to stamp out the use of non-recyclable plastics packaging*. Although sustainable polymer-based films are readily available, it is widely acknowledged that flow wrapping machines struggle to achieve a consistent pack seal due to the challenging characteristics inherent with compostable materials. Working together with innovative UK materials manufacturer Four04, Ilapak’s R&D department has developed a breakthrough heating techniques and a new sealing jaw coating to successfully seal EVAP – a clear, highgloss film which offers a high moisture vapour transmission rate (MVTR) and is compostable to the EN 13432 standard. Tony McDonald, Sales and Marketing Director at Ilapak explains: “When you’re running standard oriented polypropylene (OPP) films, it doesn’t matter if the sealing jaw temperature varies by 10deg C or so. But to consistently seal a sensitive film such as EVAP, the jaws have to be non-stick.


PECM Issue 33

The heat has to be balanced across the element and you need accurate temperature control.” The breakthrough came about when the EVAP film was being used to wrap organic own-label nuts for a major UK retailer. The breathable film holds special properties to lengthen shelf-life and, in particular, ensure that the nuts do not dehydrate. Uniquely in the UK, Four04 also provides offline micro-perforation of its films, including the EVAP used in the nut bagging application. Crucially, the size and frequency of these perforations can be tailored in accordance with the specific respiration rate of the produce being wrapped, thus optimising shelf-life. FourO4 confirms that where EVAP has been applied to fresh produce packing in the past (including soft fruit, Brussels sprouts and new potatoes), the materials company has always partnered with machinery suppliers offering the most accurate temperature control for sealing. Technical Director at UK film producer Four04 Joe Ibbotson states: “Our film runs at typical commercial speeds and at lower temperatures.” Sales and Marketing Director at Ilapak Tony McDonald says: “Having successfully modified our Vegatronic VFFS machines, we’re pretty confident we’ll be able to upgrade our horizontal machines to run EVAP and other environmentally films too.” Ilapak UK is committed to helping food factories reduce harmful plastics packaging.

ILAPAK, with its vast suite of flexible packaging solutions, can satisfy every form, fill and seal packaging requirement of the food, medical device and wet wipe industries. Besides horizontal and vertical packaging machines, its portfolio includes systems for modified atmosphere applications, product handling solutions, counting and weighing systems and complete, fully automated lines. With its headquarters in Lugano, Switzerland, Ilapak has a global presence and is part of IMA, an Italybased designer and manufacturer of processing and packaging lines for pharmaceuticals, cosmetics, tea, coffee and food.

Delivering permanent solutions for all steam trapping requirements The ECOFLOW Venturi orifice steam trap, from EBE Engineering, is the most advanced Venturi orifice steam trap on the market today. The fully flanged cast housing was designed, developed and refined using 3D modelling and casting simulation software. Producing a Venturi orifice steam trap to meet the rigorous requirements of todays steam plant users. Developed Developed on on aa modular modular concept, concept, the the ECOFLOW ECOFLOW Venturi Venturi orifice orifice steam steam trap trap encompass encompass aa wide wide range range of of capacities, capacities, from from minimal minimal condensate condensate flow flow requirements requirements on on line line drainage drainage and and trace trace heating heating systems, systems, through through to to the the high high flow flow volumes volumes and and variable variable loads loads of of process process heating heating applications. applications.

● ● ● ● ● ●

Benefit Benefit from: from: Improved Improved production production efficiency efficiency without without downtime downtime due due to to failed failed steam steam traps traps Elimination Elimination of of expensive expensive steam steam leaks leaks Reduction Reduction in in maintenance maintenance with with aa full full ten ten year year performance performance guarantee guarantee on on all all Venturi Venturi orifice orifice steam steam traps traps

Increasingly the first choice for blue chip and forward thinking businesses.

Contact us to see how we can help you

Venturi Orifice Steam trap range +44 (0)1635 282696 • • EBE EBE Engineering Engineering Ltd, Ltd, 99 Charles Charles Street, Street, Newbury, Newbury, Berkshire Berkshire RG14 RG14 6QP 6QP

Kecol Pumping Systems Kecol Pumping Systems offers solutions to many product transfer problems – read on to find out more.


ecol Pumping Systems Ltd are manufacturers of Air driven, Positive Displacement Piston Pumps and Priming Devices in polished stainless steel or carbon steel, for transferring high viscosity nonflowable products from drums and containers as used in the cosmetic, food, pharmaceutical, chemical and general industries. Products in drums or similar sized vessels that normally need to be heated in order to reduce the viscosity - can be transferred cold. Products with a viscosity up to 10,000 Poise can be transferred (cold) using the Kecol Maxiprime Pump and follower plate system and is also used to transfer pastes and products that stick to the inside of an open top drum, wiping the inside of the drum or vessel, eliminating product waste. Kecol Air Powered Drum Pumps and transfer systems are suitable for all standard size closed top or open top drums and can be adapted to suit open top containers with an internal diameter up to 1200mm. Non contact parts as well as contact parts are available in polished stainless steel, clamp - type construction is also available for hygienic applications. Typical applications in the food industry include transferring tomato

The inside of a standard 200 litre Open Top Drum is wiped clean – as the drum is emptied – with minimal product waste

puree, concentrated fruit juice, honey, fruit pastes, biscuit creams, jams, butter, margarine, sweet mince meat, sausage meat and meat pie fillings with cooked vegetables. Applications in the pharmaceutical and cosmetic industries include transferring mascara, petroleum jelly, face creams, base creams, magnesium hydroxide, aluminium hydroxide, toothpaste, lip-gloss waxes and suntan lotions.

Kecol’s articulated pump systems

Kecol’s articulated pump systems

The Kecol Follower plate system will also work on 200 litre Open Top Drums fitted with an aseptic bag – wiping the bag clean

Applications in the chemical and general industries include the transfer of paints, resins, adhesives, polymers, latex, high viscosity grease, mastic’s and inks – all pumped cold without pre-heating the products. As manufacturers, Kecol Pumping Systems can offer solutions to your particular product transfer problem, by offering a bespoke system designed to exceed your particular production requirements for single drum/vessel use or multi drum use.

Kecol Pumping Systems Ltd Faraday Drive Bridgnorth Shropshire WV15 5BJ T: 01746 764311 E:


STILL NO.1 FOR VISCOUS PUMPING SOLUTIONS With over 25 years experience in pumping viscous materials, Kecol is the number one choice of many of the World’s leading pharmaceutical, cosmetic and food manufacturers. Kecol equipment is used to transfer flowable & non-flowable materials from drums, IBC’s, mixing vessels and process vessels of various shapes, sizes and designs, without heating the material. Kecol’s extensive range of equipment is designed to transfer products from triple concentrate Tomato Paste through to Petroleum Jelly and Mascara, quickly, cleanly and efficiently from standard 200 litre drums, tapered or conical drums fitted with an aseptic bag, tote bins and IBC’s. Our vast experience has shown there are never two applications the same and that’s why we also offer bespoke systems designed and manufactured to suit your specific vessels and production requirements.

System for IBC’s

System for 4 x pallet mounted drums

Trolley Mounted Vertical or Horizontal pumps


Tel: 01746 764311

Fax: 01746 763375 Email: Here are just a few of the products we pump: • Petroleum Jelly • Magnesium Hydroxide • Mascara • Lanolin • Lip Gloss • Veterinary Creams • Eye Ointments • Paraffin Wax • Face Scrub • Teething Gels • Medical Adhesives • Toothpaste • Wax • Sun Lotions • Aluminium Hydroxide • Hand /Face Creams • Shaving Cream • Glycerine • Honey • Cake Batter • Butter • Mayonnaise • Peanut Butter • Fruit Concentrate • Margarine • Jam • Tomato Puree • Chopped Tomato • Pie Fillings • Syrups • Biscuit Creams • Caramel Products • Fruit Pastes • Cooking Fats • Fondants • Sweet Mince Meat • High Viscosity Grease • Mastic • Wood Filler • Silicon • Paint • Ink • Polymers • Epoxy Pastes • Sealants • Glue • Resin


CURTISS WRIGHT Curtiss-Wright Surface Technologies (CWST) provides high quality surface treatments which will improve the life and performance of critical components through its global network of over 70 operating divisions and specialist onsite teams.

We offer our customers a single source solution and point of contact for all their surface treatments, supporting their requirements through our global network of over 70 worldwide facilities and on-site field teams, improving and reducing turnaround times and costs.

Our surface treatments have been successfully used by OEM’s in major industries such as aerospace, automotive, oil & gas and power generation for many years.

We are specialists in protecting components from common failures and reducing maintenance costs for key industries such as aerospace, oil and gas, automotive, medical and general industrial markets.

We are only too aware of the logistical challenges and costs faced by our customers and so we can offer a “One Stop Shop” solution providing a wide range of surface treatments including Controlled Shot and Laser Shock Peening, bespoke and trade Coating Applications, Thermal Spray Coatings and Parylene Coatings for metal, alloy, plastic and electronic components as well as Analytical Services.

Building on the unique heritage of Glenn Curtiss and the Wright brothers, Curtiss-Wright Surface Technologies has a long tradition of providing innovative solutions and building solid and trusted customer relationships. Full quality and customer approvals including NADCAP, ISO 9001:2008 and AS9100 Rev C.

To find out more please visit T: 01635 279621 Shot peening is a cost effective method to help prevent: l Metal fatigue l Pitting/Fretting Engineered coatings help with: l High lubricity/low friction l Anti-corrosion l High release/anti-stick l Low noise/anti-squeak C.A.S.E.TM super finishing is used to: l Increase gearbox efficiency l Reduce surface/contact fatigue l Decrease lubricant temperature l Reduce transmission noise

Engineered technologies Surface treatments for critical components CWST are exhibiting at the Engineering Materials Live show on the 10th May and Surfex Show on 23rd and 24th May 2018


PECM Issue 33


meriflex, Inc.® provides flexible solutions from conceptual design, prototypes to mainstream production and operates on a simple philosophy based on Integrity, Service, and Quality. Our commitment to this philosophy is put into practice on a daily basis in the manufacture of our precision bellows, flanges, and other quality products. With the latest in technologies we supply a wide range of industries ranging from Semi Conductor, Medical, Oil/Gas, Food and Beverage and Automotive. Our bellows and expansion joints are designed to absorb and reduce


PECM Issue 23

vibration and relieve structural stress from working under pressure, extreme temperatures, and other variables. We specialize in thinwall bellows. We also offer the highest quality metal braided flex hose in the industry. Our braided hose is designed for high pressure applications. It provides the protection needed for the inner convoluted hose to withstand high pressure and for vacuum or partial pressure applications requiring protection from hazards. Our stainless steel braided hose can be found on NASA’s Curiosity Mars Rover, on still-in-development commercial spacecraft, and in countless other applications.

Also produced is a full line of bellows assemblies to complement our metal bellows. We manufacture bolt-style and clamp-style bellows assemblies, flanges, valve assemblies, and expansion joints. Every bellows assembly we make is ultrasonically cleaned prior to welding, and helium leak tested after to ensure weld integrity and defect-free construction.

2390 Railroad Street, Corona, CA 92880 Tel: (951)737-5557




EBE Engineering, a leading developer and supplier of Venturi orifice steam traps, has launched ECOFLOW, a market-leading steam trap that incorporates the flange into the main casting. The EFK-F and EFG-F versions are both cast in one piece, using CF8 Stainless Steel, which provide the traps with consistent strength, resilience and dimensional accuracy. The new trap’s body comprises of a modular design to incorporate low and high flow in the same housing. Due to a unique and innovative Venturi concept, the new design extends the trap’s performance over variable condensate loads. Welding has been eliminated, resulting in a totally homogenous design that makes the trap physically stronger and safer. It also simplifies certification; thereby speeding up production and ensuring consistently high quality. The streamlined manufacturing process enables EBE Engineering to pass on the benefits of economies of scale to its customers. “We are now able to assemble and supply multiple units very easily,” said Nigel Egginton, Managing Director of EBE Engineering. “The enhanced scalability


PECM Issue 33

offered by the new design, gives us far more scope to offer volume discounts to our customers”. Prior to launching ECOFLOW, EBE Engineering re-evaluated every aspect of the Venturi trap design. Then, working with NovaCast, a non-ferrous foundry, it developed and refined the casting geometry using 3D modelling and casting simulation software. A 3D printed prototype was then produced prior to full Stainless Steel production samples being commissioned. “We have converted a complex fabrication into our castings which has resulted in a truly unique solution that delivers exceptional performance to our customers as well as providing EBE with a commercial, competitive advantage”, concluded Nigel Egginton. The ECOFLOW new flanged connections are specifically designed and manufactured to meet European market requirements allowing EBE Engineering to maintain its leading position. It has now established a registered company in Germany (EBE Engineering UG, based in Essen) to specifically cater for German and EU companies by providing them with seamless ordering and guaranteed supply.

Because the ECOFLOW Venturi Orifice design has no moving parts to breakdown or wear out, it provides a lifespan that is the same as the pipework of the plant and considerably longer than mechanical traps. It also offers the ultimate in reliability, requiring no spares or monitoring equipment. For larger, nominal pipe sizes, the ECOFLOW is smaller than mechanical traps, requires less space and as the traps are lighter they provide an ideal solution where there are weight restrictions. The ECOFLOW Venturi steam traps work by using the difference in density between steam and condensate. Steam is 1000 times less dense than condensate, so at the entrance of the trap’s orifice, the low-density steam is literally squeezed out of the condensate. The high density, slow moving condensate is then preferentially discharged through the orifice, trapping the low-density steam behind it.

WORKHORSE TOOLS LAUNCH Wilkinson Star have launched a new range of Workhorse Tools to complement their popular range of Workhorse air compressors. The new range includes general air tools, impact wrenches, die grinders, sanders, riveters, drills and needle scalers as well as a range of cordless tools. These high quality tools feature premium quality components and are covered by a 2 year warranty. Workhorse air compressors are assembled in the UK and include belt drive models as well as tandem and duplex, petrol models and the recently added Yanmar diesel model. If you would like more information about this topic, please contact Tina Wilkinson Bell at 0161 793 8127 or email at

NEW COMPACT Z6R LOAD CELL OFFERS BIG SOLUTION Now available from HBM – a market leader in the field of test and measurement – is the new Z6R Bending Beam Load Cell, which has been specifically developed for use in harsh environments and applications with high requirements for hygiene. Designed for maximum capacities ranging from 20 to 200 KG and featuring an accuracy class of C3, the Z6R is particularly suitable for use in food processing, production of pharmaceuticals or packaging of building materials. tel no 0208 515 6000, email – & web –

Introducing a new range of Industrial Process Chillers

Schmersal launches new generation of position switches

The UltraChill range of process chillers go from 0.89 to 160 kW. These compact, energy efficient units are suitable for a wide range of process cooling applications and industry sectors, including automotive, engineering, food and drinks production, pharmaceutical, plastics, print and packaging, medical and scientific.

The new PS product range offers varied applications, as all the position switches can be used both as complete devices and as modular units.

The UltraChill range are available in varying formats and come with a wide range of standard options enabling easy adaption to best suit individual processes and applications. All units come with a fully corrosion resistant, nonferrous coolant circuit, including powerful circulating pump and high efficiency, copper brazed, stainless steel plate heat exchanger. For more information contact Thermal Exchange Ltd on +44 116 254 6652 or email

Reusable clamp launches in UK market to bring ease to heavy duty cable management Industrial manufacturers needing easier and more secure installation of heavy duty cables will benefit from HellermannTyton’s new reusable clamp. The Ratchet P-Clamp will change how manufacturers install cables because it simplifies the whole process whilst simultaneously leading to users saving time and money. Designed to offer versatility when managing wires, cables and hoses in all environments, the product works both indoors and outdoors. Its reusable structure allows for the possibility to fix wires, cables, hoses and pipes on a single mount in two separate work steps. For more information visit


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Type 1 position switches in line with ISO 14119 are for the position detection and monitoring of moving parts on machinery and plants as well as for lateral or pivotable protection equipment. The new range is suitable for a wide range of applications across all individual disciplines of machine and plant engineering - both for automation and safety applications and for lift engineering. The protection types IP66 or IP67 create the prerequisites for using the position switch in unfavourable environmental conditions. Additional information on the PS range can be found on our website www.schmersal., along with diagrams, brochures and the PS range YouTube video.

NEW ROCOL GREASE BOOSTS EQUIPMENT PERFORMANCE Lubricants specialist ROCOL has launched a brand new anti-seize and assembly grease to help meat processors reduce machine disassembly time, avoid damage to costly components and extend equipment life. Developed specifically for food and drink processing facilities, the new FOODLUBE AntiSeize grease prevents galling and seizure of joints and fasteners. It retains its consistency and doesn’t set firm even in high temperature or humid environments, making it particularly effective for use in areas where regular washdowns, controlled machine assembly or easy dismantling are required. FOODLUBE Anti-Seize is available at Acorn. For more information about the product visit

You’re an OEM?

Need a customised embedded PC solution? BVM provides:● Design - electronic & mechanical CAD services ● Test - functional, environmental & compliance ● Manufacturing - OEM label, BOM control, warranty

At BVM we have many years experience in the design and manufacture of embedded PC systems and panel PC’s. Whatever you application, talking it over with an experienced engineer might just give you that inspiration you need. Very likely we can provide that resource you’ve been looking for to ensure your project is a success.

Call us today to discuss your project What have you got to lose? Call: 01489 780144





image © GEA Pharma Systems

Through a collaborative partnership, GEA Pharma Systems, Siemens and Perceptive Engineering have developed a comprehensive Real Time Platform for model-based monitoring, controlling and reporting system performance for GEA ConsiGmaTM manufacturing equipment. Based on the Siemens SIPAT TM PAT Management System (PMS) and Perceptive’s PharmaMV TM Advanced Process Control platform, the system has been developed to provide: •

• •

SIPAT integration including calculation engine for Real time Multivariate Calibration Models and data export using SIPAT data miner. Model Development and Maintenance facilities for Calibration, Control and MVA models. Real Time Quality monitoring using Univariate SPC and Multivariate SPC for Continuous Process Verification


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• •

Advanced Process Control solution for precise control of key processing stages (granulation, drying, compression). Comprehensive User-Configurable Dashboards, Key Performance Indicators and reporting

PAT Management System SIMATIC SIPAT can be combined with different analytical devices and provides comprehensive functions for the configuration and control of measuring devices. SIMATIC SIPAT collects all device data and controls the performance of the devices. The user benefits from a uniform interface for different analytical devices, for example, through easier training and operation.

Data Collection SIPAT can be used in combination with the most popular process analysers in production, in research and development, and in process development. Open industry standards are used for the reliable measurement, collection, and transfer of information and for exchange with third-party systems such as process control systems. SIPAT also considers offline or online quality parameters that are either collected in a laboratory information management system (LIMS), entered manually in the Supervisory Control and Data Acquisition (SCADA) system, or entered directly in SIPAT. Data from different sources or even from different sites can be consolidated for better evaluation.

Compliance with legal requirements and 21 CFR Part 11 SIMATIC SIPAT and PharmaMV provides a comprehensive audit functionality, which enables compliance with legal requirements and 21 CFR Part 11. The most important audit function blocks of the software are as follows: • • • • •

System safety and authorization controls Electronic signatures Recording of all changes to data sets Recording of reports and reproducibility in the online database and in the archived data Version control for objects such as PAT methods, models, device settings, etc.

KEY FEATURES: PAT CALIBRATION MODELS Calibration model development and execution using the PharmaMV engines integrated into SIPAT. Flexible preprocessing, model building and traceability tools. Calibration models developed for Critical Quality Attributes such as drug potency.



Mechanistic (via gPROMS) and empirical steady state and dynamic models for soft sensors, monitoring, control and optimisation, executed open (Advisory Mode) or closed loop. Continuous and batch models, parametric and non-parametric options.

Univariate and multivariate visualisation tools including SPC charts, contribution/ score plots, trends, built to support process monitoring and control. These visualisations can be added to HTML5 dashboards and embedded in the GEA SCADA.

All model parameters, predictions, performance metrics available via intuitive user interface. Models developed for CDC, TSWG and FBD process units.

PROCESS MONITORING using SPC, MVSPC Real Time Shewhart, EWMA and CUSUM charts with Western Electric Rules, automated Outlier detection and alarming. Full suite of templates for multivariate process monitors using Principal Component Analysis, Partial Least Squares, with Multivariable Alarm Thresholds for the ConsiGma Units. MVSPC plots with SPE & T2 statistics provided for real time monitoring. Complete Multi-Model Operating Modes, Fault Fingerprints, Fault Diagnosis tools developed for the ConsiGma Units. Full integration with GEA’s platform.

CONTROL ENGINEERING Full integration with GEA’s Dynamic Process Control interface with recipe-driven support for Advanced Process Control. Model Predictive Control and optimisation is available for key process units in the ConsiGma line. PharmaMV APC provides combined feedback and feedforward control of predicted Critical Quality Attributes using PAT derived or mechanistic models.

Iris offers Efficiency Benefits


Iris recognition provides the ultimate human identification system interfacing to today’s modern technologies and is the World’s most accurate biometric.

Now available from HBM – a market leader in the field of test and measurement – is the very latest EVIDAS software, which is designed to significantly accelerate and facilitate data acquisition.

Non-invasive and non-contact providing contamination free use. Offering 1: n identification without the need for cards, tokens, pin or passwords in less than 1 sec.

Simple to use, EVIDAS software features an intuitive user interface that provides immediate visual feedback.

Ideally suited for Time & Attendance and access control across all industries including mobile worker log in with hand held units.

By simply connecting the smart sensors (TEDS), it takes two simple clicks to display measurement results, without any programming, saving users valuable set-up time and effort, which is a considerable benefit for those on the move.

Can be integrated with process control equipment to allow identification of a person to ensure they are qualified to use and for audit control of the process.

For further information, please contact HBM on +44 (0) 1525 304980 or via email: or visit the HBM website at

DELIVER FAST, RELIABLE, SCALABLE CODE Simply modernize your high-performance computing, enterprise, and cloud applications for faster, scalable, and portable parallel code. If you’re developing an application that has a problem to solve, a simulation to run, an image to analyse or any other task that turns data into information, Intel Parallel Studio XE 2018 will help your software to run faster, to help you do more complex work in the same amount of time, including big data analytics, machine learning applications, and time-critical financial analysis. What it does: Intel Parallel Studio XE 2018 is a suite of tools that simplifies the design, building, verification, and tuning of applications that run in parallel including thread parallelism, vector parallelism, and MPI process parallelism for C++, Fortran and Python developers running on Windows, Linux or Mac. It helps to modernise your high performance, enterprise, computing and cloud application to enable faster, more scalable and portable parallel code.


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• • •

Let’s you develop faster code to boost application performance. Harnesses the full potential of today’s and next-gen processors. Speeds the design process by identifying the issues blocking effective vectorization and suggesting solutions. Helps you code faster with a toolset that simplifies creating fast, reliable parallel code.

Want to learn more? Contact Alfasoft at or +44 (0) 203 695 7810

Boost Your Productivity with real-time Attendance Recording Autotime Solutions provides the latest cloudbased Time & Attendance for manufacturers of all sizes, with a low cost monthly fee. With over 20 data capture options available you can choose from fingerprint, face recognition, hand scanners, palm readers, mobile apps, card readers or even telephony. Key features include real-time absence alerts, emergency muster reports, remote enrolment and automatic timesheet population for streamlined payroll. Available as a standalone system or as part of an integrated Access Control, HR and Workforce Management solution. Tel - 01438 822183 Email -

The secret ingredient that ensures the bread always rises

Agility is a flexible, dynamic asset and maintenance management platform that maximises uptime and minimises production disruption. Identifying the causes of repetitive maintenance and downtime is essential to reliable production. Agility is delivered and fully supported by SoftSols, a global manufacturing solutions provider, so you have the reassurance of a technology you can trust and rely on. The result is more efficient (and rising) production levels.

Take a look at our case studies to discover Agility in action at or call us on 01924 200344 today.



APD DOUBLES THROUGHPUT WITH THE HELP OF A BITO STORAGE SOLUTION A BITO Storage Systems installation has helped Autoparts & Diagnostics (APD) transform its central warehouse operation for the UK by giving extra capacity and a more efficient picking operation through greater density of storage. In July 2017, leading supplier of top quality automotive parts, tools and diagnostic equipment, APD moved into a new central warehouse just across the road from its existing facility in Tewkesbury, Gloucestershire. BITO racking, shelving and carton live flow lanes with XL containers give the space capacity that APD needs inside the new facility to establish new and more efficient work processes. This will result in a throughput this year of 4 million items, doubling what was achieved in the old warehouse. Enjoying consistent growth over the last 9 years, APD needed a building that could accommodate that trend for the next five years. The company supplies a broad range of automotive parts from 50 different suppliers – anything from small spark plugs, right through to heavy clutch kits. The range is constantly evolving as APD takes on more suppliers and looks at new opportunities. Throughput of the product in the old warehouse was a major challenge, according to Charlie Baker, Operations Manager at APD. He says: “We had a warehouse and layout that was fit for purpose of an operation of about half the size of ours.” The new building offered more warehouse capacity and the company turned to external consultant, Chris Lima, for advice. “Carton Live Storage and the drive through racking were a core part of the project that we developed with BITO to maximise the space and integrate with the way we want to work.” According to Lima, the BITO installation has not only increased capacity of storage but it has also been a catalyst for the introduction of more customer-centric process in its new warehouse. Orders are picked as soon as goods arrive, with incoming pallets placed straight on the warehouse floor in the middle of the building. Once a pallet for an order is complete, it’s wrapped, labelled and


PECM Issue 33

put into a customer-specific area of the drive through racking, ready for customer collection. The narrow aisles are served by an articulated forklift truck, saving space on the counterbalance lift truck / wide aisle combination of the old facility. BITO’s drive through racking design accommodates different pallet sizes and also allows double stacking, when possible, which reduces the overall number of lifts by up to 60%. “Sometimes clients order small amounts of a certain product from a certain supplier, which were kept in a palletised backorder tub,” says Lima. “This was space-inefficient in the old warehouse because we needed a pallet for each customer, which meant a significant number of pallets were lined around the sides of the warehouse at varying levels of being full or empty. We saw carton live as an opportunity to condense this storage from a space perspective.” The Carton Live Storage (CLS) provides 11 bays of flow lanes, giving small parts storage for 16 customers per bay on the opposite side of the warehouse to the racking. APD spent time with BITO to find the right height for the flow lanes and to select the right container to match its products, which turned out to be the BITO XL 800 mm x 600 mm x 320 mm high storage container. BITO retrofitted the carton live flow lanes onto racking brought over from the old warehouse. Stock that APD holds is located on rows of BITO boltless galvanised shelving, which has been designed to fully optimise the space. In the old warehouse, this stock was all on pallet racking, hogging space. BITO commenced installation after Easter 2017, working closely with APD on phasing the

work to ensure business continuity while the existing racking was transferred to the new facility. “It was a big jump from what we had to what we were moving into,” says Lima “Having BITO’s constant support, the ability to consult with them regularly and play around with equipment in BITO’s facility was crucial. Installation was completed in mid-July and since then we have been constantly refining our process as we go.” Lima also highlights how the new process has created safer work practice by segregating pedestrian operatives in the warehouse and the articulated forklift trucks within the racking. Baker concludes: “We now have a facility that we are proud to show to customers. The BITO installation has allowed us to change our processes, which has made us a lot leaner. The new warehouse design has allowed us to change our strategy and be able to adapt to changing requirements.”

About BITO Storage Systems: With its head office and main production facilities in Germany, BITO is an internationally operating manufacturer of storage and order picking systems. The company’s product range includes shelving and racking; storage and order picking systems; bins and containers and warehouse equipment and accessories.


Move, handle and reconfigure with ease HART DOOR SYSTEMS

The ability to reconfigure and upgrade Graphit® systems means operatives can quickly change the shape and function of storage units to suit new materials and work area layouts.

Hart’s flagship Speedor Super high speed door, seen here, has been in continuous production since 1983 and many thousands of doors have been installed on challenging sites across the world.

Graphit enables solutions that provide much-needed lightness and easeof-handling when it comes to order preparation. The system’s modularity makes it easier to cope with varying customer volume profiles because installations can be dismantled, stored and rebuilt in response to seasonal business and workforce variations.

Speedor Super, the leading door brand from Hart Door Systems, is in demand for its energy saving, high speed door, and environmental standards.

The KIS Double Cantilever Advantage

Tel: 01295 277791


The unique KIS beam design allows moving or sliding of the load point with negligible effect on the output.

Bulk Material Handling and Packaging High Accuracy ProcessProcess Weighing Performance System Improves

Used predominately as an external door with good wind resistance and often in high traffic situations, Speedors are built to last through their robust and reliable construction.

For processes where liquids, powders

Speedor Super’s main features include tensioned door curtain, sophisticated, state of the art control with a host of features, variable speed options including soft start and safety systems including safe edge deep rubber seal on the leading edge of the door. Options include a break-out feature and full width vision panel. The size range is up to 6M wide and 6M high.


The Tube and Bracket Company designs and supplies modular Graphit® solutions that are easier to move and handle, allowing rapid reconfiguration of production line and storage systems. t: 0191 214 0404

National Bulk Equipment, Inc. (NBE). granules are and measured. NBE orintroduces thismixed automated, bulk material handling and packaging system built on the NBE integrated construction and controls infrastructure. The complete process sequence, including: pallet/base supply, slipsheet pick-and-placement, bulk material infeed, packaged contents isolated Thermal Expansion Vibration Twisting Forces densification, NTEP-certified weighing, and finished-package accumulation conveyance • operates on paired, process-specific structural framework chassis with all automation and control functions centralized to a single, menu-driven HMI to enable standardized and system-wide data reporting. The NBE integrated construction and controls infrastructure provides the basis for reduced total cost of ownership, relative to the common systems integration concept of bolt-together, divergent ‘islands’ of equipment, while also improving process performance and the accuracy of production data shared throughout the enterprise.

©2017 Vishay Precision Group, Inc.

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C3412 – The new generation “Compact Crane”

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Stowed: Only 2m high, 1m wide and 2.9m long Reach: 21m

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With unique infinite outrigger positioning technology, the versatile C3412 can be set up and operated in the most demanding of confined spaces. Hybrid technology allows it to operate internally or externally around production lines or construction sites.



This compact crane has a maximum lifting capacity of more than 4 TON!!! Reedyk compact cranes dealer for the UK and Ireland •


PECM Issue 19

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THE CHALLENGE OF PHARMACEUTICAL LOGISTICS: MASTERING COLD CHAINS AROUND THE WORLD In the pharmaceutical logistics sector, maintaining the cold chain has always been a top priority. This is now proving to be a key concern for pharmaceutical manufacturers. Biopharmaceuticals, in particular, contain active ingredients that are difficult to produce and are highly sensitive to physical influences. This leads to stricter quality assurance requirements both in production and during the transportation process. The regulatory provisions for shipping medication – which are becoming more stringent all the time – and the globalisation of supply chains are bolstering this trend. To meet these requirements, pharmaceutical manufacturers need to plan their logistics processes meticulously and at as early a stage as possible. One major challenge is to take into account the various conditions and provisions in the respective countries of origin, transit and destination. Logistics4Pharma specialises in planning and implementing the temperature-controlled delivery and storage of sensitive pharmaceutical products according to GDP standards. “We are the point at which all the threads come together. This is essential, as a lack of communication between the individual parties involved in the process can lead to key information becoming lost,” states Manuel Zollondz, CEO of Logistics4Pharma. Global expertise in shipping and cuttingedge technology In addition to an awareness of the specific elements involved in global freight handling, it is crucial to select the right packaging and storage option and to monitor the valuable, sensitive cargo in a reliable manner. Logistics4Pharma provides GDP-compliant, temperature-mapped and continuously monitored storage facilities at Frankfurt Airport, one of Europe’s foremost freight hubs, with options including controlled room temperature storage, refrigerated storage and frozen storage. In terms of shipping, the company’s internally developed thermal packaging systems are able to maintain a stable temperature for up to 120 hours. Meanwhile, calibrated temperature data loggers for various temperature ranges


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are activated at 15-minute intervals for up to 166 days, thereby ensuring continuous temperature tracking. By way of example, when Logistics4Pharma transported 120 kg of frozen pineapple samples from the Philippines to Ulm (Germany), the temperature remained consistently below -60 °C throughout the journey. For road transport, the vehicles in the Logistics4Pharma fleet – which are GDP compliant and tamper-proof – provide GPS and temperature tracking in real time. Direct deliveries for individual customers prevent fluctuations in temperature. The Logistics4Pharma team is highly experienced and has been trained in good distribution practices, and selects the means of transport based on the specific product requirements, preferred routes and/or transit times. “We pay attention to the details well in advance of the actual transportation of the goods. As a link in the overall production chain, logistics is often underestimated. A cost-effective solution can sometimes turn out to be the best one. Where the pharmaceutical sector is concerned, though, the element of chance should not be relied on if it can be helped,” states Manuel Zollondz when discussing the role played by logistics in pharmaceutical production.

Further information is available at

The KIS Double Cantilever Advantages Advantage 1: We start with the best gages and the best gage configuration. KIS Beam technology incorporates SR-4® foil strain gages connected as a full Wheatstone bridge that is temperature compensated and calibrated to deliver accuracy and reliability. All KIS beams are factory-calibrated for quick, easy installation and setup with no need for on-site calibration.

Force applied directly to the sleeve (cutaway) over the gage pocket area

Advantage 2: The KIS Beam’s cylindrical design enables KIS beams to be rotated within the module hardware to coincide with the exact direction of applied weight. The electro-polished stainless steel provides a nearly frictionless surface for the module yoke to slide on during periods of thermal expansion and contraction. BLH NOBEL—Your Partner All The Way As your partner from start to finish, we provide the right system for your specific needs, along with extensive technical documentation to support safe and efficient product designs, to ensure smooth installations and reliable, long-running service.

BLH Nobel

Movable load point

Airedale House, Canal Road | Bradford, West Yorks BD2 1AG Phone Number: +44 1274-782 229 | Fax Number: +44 1274782230 Email:

Electronica 2016 Advert_Print.pdf 1 10/6/2016 11:10:40 AM

Electronica 2016 HALL B1 BOOTH 121 November 8-11th Messe München









Tel: 44 (0) 1255 862236

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Gericke RotaVal valves are built to last a life-time when carefully maintained and serviced. The valves have an 18 month warranty. Gericke RotaVal view the sale of their valves as just the start of the partnership with their customers and have launched a full aftersales service called RotaCare. On-Site Surveys: If customers are not sure what they need or having difficulties with existing valves an on-site survey can be arranged that will give some advice and point customers in the right direction. Training: When valves have been delivered, there may be need for support and training during installation. Gericke RotaVal have the ability to supply an experienced engineer to offer guidance through the process. This is chargeable but well worth the investment.

Servicing & Maintenance Contracts: Gericke RotaVal can arrange to regularly service rotary valves to maximise performance. This can be a one-off or an annual arrangement. Spares: Gericke RotaVal offer a full spares programme to keep customer’s production up and running.

refurbished or whether it is more beneficial to purchase a new one. Refurbishments include new parts and a repaint to return it to new condition Full details can be seen on the website RotaCare Hotline: + 44 1249 705 629 Email: Website:

Refurbishment: There is a strip and inspect service that gives customers detailed information whether their valve can be


DIXON LAUNCHES RANGE OF MIX PROOF VALVES Dixon announces the extension of its wide range of hygienic process valves with the addition of the Dixon Rieger range of Mix Proof and Double Seat valves both hygienic and aseptic. The range includes Mix-Proof valves, double seat valves which are an economical alternative to mix proof valves, hygienic pressure resistance valves, hygienic overflow valves, tank bottom, pigging (product recovery) valves and regulating valves. Applications Food and beverage, dairy, bio-processing, pharmaceutical, and cosmetics where aseptic and hygienic conditions are required and clean ability is paramount.

Features Thanks to a modular block design, changing over to an aseptic design is possible for the single seat valves. Dixon Rieger valves are completely drainable and have a dead space free design. All valves come with Ra 0.8µm. Higher specification polishes and electro polishes are available. Solid housings manufactured from solid 316L bar and exotic materials such as Hastelloy are available. Certified to EHEDG and 3A. Innovative Design Dixon Rieger valves offer a market leading hygienic design; •

Simple and quick assembly without any special tools.

“With this new range we are pleased to offer Dixon customers a full range of hygienic process valves which now include ball, butterfly, seat, check, sample, diaphragm, and of course the mix proof valves.

Less seals in comparison to other similar products ensuring less failure and reduced costs associated with maintenance and optimized spare parts holding.

Our customers know all they have to do is make one phone call to Dixon!” says Dixon’s Hygienic Products Manager Ike Topselvi.


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The opening mode of the pneumatic actuator may be changed by a simple device modification from “air open –

spring close” to “spring open – air close” and vice versa. •

Screwed pneumatic actuators for easy maintenance

About Dixon Group Europe Ltd Dixon Group Europe Ltd is based in the North West of England, and is part of the Dixon Valve & Coupling Company (USA), the world’s leading manufacturer and supplier of valve, hose and coupling products for use across a wide range of industries. Dixon Group Europe operates within Europe from locations in U.K, Germany, France, Russia, and UAE. Dixon’s hygienic and pharmaceutical range of products include; fittings, tubing, hygienic unions, manual and automated valves, pumps, hoses and hose assemblies and a range of accessories. Contact Gill Platt @ Dixon Group Europe Ltd T: +44 (0) 1772 323529 E:


Big-waves · Nazaré · Portugal


When it comes to face massive amounts of pressure and condensed energy there are no place for mistakes.

We are experts in uid control systems.

STEAM TRAPS | PRESSURE REGULATORS CONTROL VALVES | HEAT EXCHANGERS AND MUCH MORE Zona Ind. da Guia, Pav. 14 - Brejo · 3105-467 Guia PBL PORTUGAL · (+351) 236 959 060 ·



VALSTEAM ADCA ENGINEERING SA At Valsteam Adca Engineering SA we are completely focused on providing groundbreaking products for industrial steam and fluid systems. The project started more than 35 years ago, as industrial pipeline and steam boiler house contractors, already building pressure vessels and auxiliary equipment in-house. Since then we have grown up to become a full-service steam equipment and valve manufacturer, assuring the complete production cycle: design, machining, welding, assembly, tests, quality and packaging. The company started small, with its first manufactured product being the thermodynamic steam trap, followed by float and thermostatic steam traps, pressure operated pumps, humidity separators, and heat exchangers. Up to now, the company consolidated a very wide range of products and solutions for steam and other industrial gases, present in the process industry. “Today, we can proudly stand as a “one stop shop” with more than 6.000 different products and more than 15.000 product parts for all kind of industries.” From standard and non-standard series to tailor-made products Valsteam Adca is one of the European companies with the largest range of products. The product range can be divided into six sections: steam traps, pressure reducing valves, control valves, pipeline ancillaries, special construction equipment and Adca pure, the hygienic/sanitary line. Today Valsteam ADCA has two production facilities with a total manufacturing capacity of 22 000 square meters, located in a small village in the ocean side of Portugal.


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The team today consists of 70 people that together drive this Portuguese caravel along in five continents and more than 80 countries, with the same ambition their ancestors were driven by: to reach more. We are now a global company, but we kept the best that a family owned business can keep: agility in developing new products, the flexibility in production and the proximity to our staff and clients. The requests of our clients for different special products encounters in our company the willingness and determination for accepting new challenges, leading us to always look to and invest in state of the art machinery supported by advanced engineering softwares that allow our teams to continuously increase the productivity and the quality of the products.

Come visit us at

Control Valves & Pressure Regulators •

Richards Industries Control Valves and Regulators designed with the benefits of sliding gate technology

High turndown ratios, low turbulence, self-cleaning, compact size, straight through flow

Responsive – fractional control of gas & liquids

Exotic and standard materials, various end connections and sizes

Fast delivery on standard product

High reliability, low cost of ownership

Applications include high pressure, low flow, and cryogenics for OEMs and R&D industries

01895 200015 22 Sarum Complex, Salisbury Road, Uxbridge, Middlesex. UB8 2RZ

• • • • • •

Fully Machined from Stainless Steel Rapid Access for Cleaning Full Clean-in-Place Increased Productivity Minimum Down Times FDA Double Lip Seals

+44 (0) 1249 651138

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HYGIENIC PROCESS VALVES Hygienic & Aseptic Range


• • • • • • •

• • • • • • •

Single seat, Double seat (Mix-Proof) Hygienic pressure resistance Hygienic overflow Tank bottom Product recovery Regulating Sample

Leak free change over Modular block design Manufactured from solid 316L bar (exotics available) Fewer product contacting seals for ease of maintenance No special tools required Fully balanced & drainable Certified to EHEDG and 3A

For further information please contact us now:

01772 323 529

01772 323 529 • •

©2018 Dixon Group Europe Limited

WESTINGHOUSE Servicing & Repairs of Rotary Valves and Diverter Valves Free of charge assessment by a DMN engineer Genuine spare parts used to the original manufacturer’s specification Comprehensive 12 month warranty with continued support with all refurbished DMN valves Refurbishment service by the original manufacturer ATEX certification and validation services

DMN UK Ltd. T +44 1249 818 400 130

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New for 2018: Veriflex® is the latest range of industrial automation cables for control and fieldbus applications. Veriflex SY, CY, YY, PUR, Servo and BUS cables offer verified quality and compliance, combined with next-day availability from our UK stockholding and extended product warranty. “As the first company to achieve the BSI Cable Batch Verification Kitemark, Eland Cables sets a new benchmark in cable compliance. The Kitemark is applied to products, including the Veriflex SY, CY and YY range of PVC and LSZH control cables, under strict UKAS test parameters and subject to BSI’s rigorous surveillance programme.The range of tests provide third-party assurance that cables meet relevant British and international standards for key safety criteria, making them fit for use in appropriate applications.”