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PWE
Since 1981

www.pwemag.co.uk
Plant &
Works
Engineering
@plant-&-works-engineering
August/September 2023
| Issue 476

@PWEmagazine1

Digital technologies
in maintenance
page 10

Inside this issue:

30 > Thermal Oxidisers: Efficient odour abatement
36 > Want a safer workplace? Then show the value
40 > Sustainability through supply chain management

NEWS | FEATURES | PRODUCTS | CASE STUDIES

 As one of the UK’s largest stockists of stainless steel pipes, fittings and
valves, Nero are committed to providing the best customer service and
quality of product available. Our new ‘one stop shop’ e-commerce website
will enable you to check specification, price and availability and then
complete your order with minimum fuss.
With over 5000 stock items, we offer worldwide same day dispatch before
4:30pm and have one of the latest cut off times in the industry.
Visit www.nero.co.uk and begin to benefit from end-to-end service today.

nero.co.uk | +44 (0)121 665 3900 | info@nero.co.uk

Unit 2, Union Rd, Anglo African Industrial Estate, Oldbury, West Midlands B69 3EX

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Editor’s Comment

The need for a

collaborative approach
A
s we approach the end of in bolstering local economies, offering and regional aspirations. A strategic
summer, our attention a vantage point beyond geographical approach, amalgamating a
inevitably looks to the significance. nationwide industrial vision with
potential outlook for the The concept of “levelling up” also localised growth strategies, holds
remainder of the year. The recent emerges, acknowledging both potential for harmonising regional
Make UK Regional Manufacturing progress and disparities. The Report strengths, including infrastructure,
Outlook report provides an interesting acknowledges the distinct recovery innovation, and skill development.
overview that not only sheds light on trajectories, with London and the South The increase in manufacturing jobs
the sector’s present state but also East leading the charge post- as highlighted in the Report serves as a
prompts a nuanced reflection on the pandemic. This disparity underscores testament to the sector’s resilience,
challenges and potential opportunities. the complexity of equalising weathering the storms of Brexit, labour
Its emphasis on the apparent opportunities across regions, challenges, and supply chain
increase in manufacturing jobs across challenging the notion of a level complexities. Recent energy price
six of the eight English Regions and playing field. fluctuations, attributed to geopolitical
Wales draws attention to the sector’s The manufacturing sector’s tensions, accentuate the sector’s
potential to generate employment and contribution to the economy, exposure to global dynamics.
stimulate economic progress. characterised by high-value and skill- Looking forward, uncertainties
Particularly noteworthy is the significant intensive jobs, remains a central tenet persist. Escalating inflation and interest
jump in manufacturing jobs observed in of the drive toward balanced regional rates cast a shadow of uncertainty
Yorkshire & Humber. This upswing in growth. Yet, the report stresses that over economic stability, warranting
employment in these regions achieving this necessitates measured, prudence and adaptability. However,
underscores the role of manufacturing cohesive strategies that align national the sector’s resilience to these potential
challenges will invariably be an
indicative test of its long-term
sustainability.
Against this backdrop, the Make
UK/BDO Regional Manufacturing
Outlook report calls on policymakers,
business leaders, and communities to
forge a collaborative path. By nurturing
cooperation, implementing
comprehensive strategies, and
embracing innovation, the
manufacturing sector could catalyse a
more robust and balanced economic
landscape.

‘ ’
By nurturing cooperation, implementing comprehensive strategies,
and embracing innovation, the manufacturing sector could catalyse a more
robust and balanced economic landscape.
August/September 2023 www.pwemag.co.uk Plant & Works Engineering | 03
 Call for nominations
now open...
Giving special thanks and recognition to the people, companies, projects
and services that play a crucial role in ensuring our food production, utilities,
manufacturing processes, transportation and other essential services are
maintained and secured.

Endorsements:

“The AEMT Awards is one “We were delighted to win

of the highlights in the the Diversity in Engineering
industry calendar, and ABB is category. The AEMT Awards
delighted to have sponsored are a fantastic opportunity
the ‘Service Centre of the to network and share best
Year’ Category since 2018. I’d practice within our industry.
like to thank the organisers It’s great to see so many
and offer my congratulations businesses driving innovation
to all finalists and winners on and advancement.”
the night.”
Eleanor McIntosh
Rob Wood Houghton
ABB, UK International

Thursday, November 23rd 2023

DoubleTree by Hilton Hotel, Coventry
The awards are a global celebration of business and professional excellence. They recognise the achievements of both
individuals and companies manufacturing, distributing, maintaining and repairing industrial machinery such as electric
motors, drives, pumps, fans, gearboxes, generators, transformers, switchgear and ancillary equipment.

There are 7 categories to choose from including: Product of the Year, Project of the Year, Supplier of the Year, Service
Centre of the Year, Diversity in Engineering, Contribution to Skills & Training and the Rising Star Award. Make sure
you enter now to be recognised as a leader in your industry.

Online Entry at: www.aemtawards.com

2023 Partners:

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Contents

Editor:
Aaron Blutstein
t| 01732 370340
e| editorial@dfamedia.co.uk
Content Sub Editor:
Leslah Garland
t| 01732 370340
e| leslah.garland@dfamedia.co.uk
Sales Director:
Damien Oxlee 10 12
t| 01732 370342
e| damien.oxlee@dfamedia.co.uk
Sales Manager:
Andrew Jell 30 36
t| 01732 370347
e| andrew.jell@dfamedia.co.uk
DFA Direct:
Ian Atkinson
t| 01732 370340
e| ian.atkinson@dfamedia.co.uk
Production Manager & Designer:
Chris Davis
e| chris.davis@dfamedia.co.uk
Marketing Executive:
Hope Jepson
e| hope.jepson@dfamedia.co.uk
COMMENT 3
Operations Manager:
Emma Floyd
t| 01732 370340
NEWS 6
e| emma.floyd@dfamedia.co.uk A round-up of what’s happening in industry.

Reader/Circulation Enquiries:
INSIGHT 10
Perception
t| +44 (0) 1825 701520
e| cs@perception-sas.com MAINTENANCE MATTERS -
INCORPORATING PROBLEM SOLVER 12
Financial: Focus on: Plant & Asset Management/ Preventive & Predictive
Finance Department
Maintenance/CMMS
e| accounts@dfamedia.co.uk
Optimal utilsation of assets, low downtime and low maintenance costs ensure the
Managing Director: Ryan Fuller highest possible productivity. This requires an intelligent EAM solution for registering
e| ryan.fuller@dfamedia.co.uk and analysing the data.
Chief Executive Officer: Ian Atkinson
e| ian.atkinson@dfamedia.co.uk PROCESS, CONTROLS, & PLANT 20
Published by: Focus on: Compressed Air/ Seals, Bearings & Lubrication
Cliff Warne, BCAS Executive Director explores the importance of compressed air
system design to ensure energy performance is optimised, highlighting the various
options available to calculate the annual running cost of an air compressor, while also
advising on how best to design an energy-saving system.
DFA Media Group
192 The High Street, Tonbridge, Kent TN9 1BE ENERGY & ENVIRONMENTAL MANAGEMENT 30
t| 01732 370340
e| info@dfamedia.co.uk Focus on: Boilers, Burners & Controls/ HVAC
w| www.pwemag.co.uk Etienne Fourie, Technical Sales Manager at Babcock Wanson, explains the use of
Official Supporters: Thermal Oxidisers in the food industry.

HANDLING & SAFETY MATTERS 36

BCAS official Focus on: Health & Safety
media partner

Printer: Warners, UK
Having recently achieved the ISO 45001 certification for Air Products, Rachel
© Copyright 2023, DFA Manufacturing Media Ltd Rawlings, talks about why plant operators and engineers are central to the success of
ISSN 0262-0227
PWE is a controlled circulation magazine, published 11 times a year.
occupational health and safety initiatives.
Please contact DFA Media with any subscription enquiries. Paid
subscriptions are also available on an annual basis at £100.00 (UK) or
£170.00 (Overseas) P+P included. The content of this magazine, website SPECIAL FOCUS
and newsletters do not necessarily express the views of the Editor or
publishers. The publishers accept no legal responsibility for loss arising from
SUSTAINABILITY & NET ZERO 40
information in this publication. All rights reserved. No part of this publication
may be produced or stored in a retrieval system without the written consent
of the publishers. PRODUCTS & SERVICES DIRECTORY 42
August/September 2023 www.pwemag.co.uk Plant & Works Engineering | 05
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News

British Compressed Air Society appoints Cliff Warne to Board

The British Compressed Air Society materials and costs or compliance with experience in the industrial sector, combined
(BCAS) has appointed Cliff Warne as legislation, end-customers are looking for the with his proven leadership skills will be a great
Executive Director. best advice from their suppliers to mitigate for asset to the Society.
Cliff, who joins the Society with a wealth of these risks. “Vanda and Cliff will work together during
engineering and commercial experience “This is where BCAS has an important role this transition period to continue to deliver best
gained in manufacturing and process roles, to play – acting as an independent, trusted value for our members and to ensure the
will work alongside Vanda Jones, during an source of advice and I very much look forward Society remains a source of independent and
initial transition period. to working with end-users to help improve the trusted advice to compressed air end-users.”
Starting his career as an engineering trainee efficiency of their compressed air systems.
at Mars Confectionary, Cliff is a well- “Our BCAS members are equally important,
respected figure in the pump and process and I am keen to build on the excellent
market, having worked for over 20 years at achievements of Vanda and the team and to
AxFlow. This included 15 years in leadership continue to work closely with our distributor,
roles as well as engineering and product manufacturer and end-use members. This
management roles. It is this proven track includes our important lobbying work to ensure
record of engineering sales and building the best outcomes for end-users as new
strong commercial relationships that Cliff will legislation and regulations are introduced, as
take into his new role with BCAS. well as continuing to develop our training
Warne commented: “I have supported portfolio.”
customers in a diverse range of industrial Commenting on Cliff’s appointment, Mark
sectors, from chemical to oil and gas, food Ranger, BCAS President added: “We are
and beverage to nuclear industries and delighted to welcome Cliff to the BCAS team
understand the challenges they face. Whether and send him a very warm welcome from all
it’s the rising cost of energy, managing raw of the BCAS board members. His wealth of

AEMT Awards entry deadline fast approaching

Time is running out to of talks and presentations specifically designed • Rising Star Award – sponsored by TEC
prepare and submit to be of tangible value and relevance to all Electric Motors
nominations for the those companies operating across the • Diversity in Engineering Award – sponsored
2023 AEMT Awards engineering service and maintenance arena. by Preformed Windings
Programme. With the The AEMT Awards programme will again • Lifetime Achievement Award – sponsored by
final entry date set as acknowledge the skill, effort, and dedication of AEMT
5pm on Friday 8 the people and businesses serving this
September, the AEMT again looks forward to important industry sector. With sponsorship Entries are being sought for any company,
recognising and rewarding business and provided by a host of leading industry names, product, application, or individual involved
professional excellence across the electrical including ABB, DFA Media Group (publisher of in the supply, installation, service,
and mechanical repair sector. Drives & Controls and Plant & Works maintenance and repair of industrial
Building on its past successes, the fifth outing Engineering magazines), EMIR Software, TEC machinery technology such as electric
of this sector specific awards scheme will Electric Motors, Megger, Sulzer, motors, drives, pumps, fans, gearboxes,
culminate in a gala presentation ceremony to be Menzel, and Preformed Windings, well generators, transformers, switchgear, and
held on the evening of Thursday, 23 November, deserved industry-wide recognition will be ancillary equipment. Individuals can put
at the Doubletree by Hilton Hotel in Coventry. given to those businesses which are excelling in forward entries for themselves and their own
This venue will also play host to the their commercial endeavours. company or nominate others that they
supporting AEMT Conference taking place believe merit recognition. The online entry
throughout the day. The full programme is Award Categories: process is quite straightforward, and anyone
currently being finalised, but its focus will again The seven categories that make up the 2023 wishing to play their part in highlighting
be on providing AEMT members with help and awards programme are: engineering excellence should visit the
guidance on a range of topics of primary • Product of the Year – sponsored by DFA AEMT Awards website –
interest to the development of their businesses. Media Group www.aemtawards.com.
Staff recruitment, development and retention, • Project of the Year – sponsored by EMIR It is free of charge to enter the awards, but
the adoption of smart technologies, the Software the promotional value associated with being
commercial value associated with circular • Service Centre of the Year – sponsored by selected as a finalist is worth many hundreds of
economy and sustainability initiatives, and the ABB pounds. But for those individuals and
support networks that can be accessed by • Supplier of the Year – sponsored by companies fortunate enough to be announced
those operating in the sector will all be Megger as one of the seven winners during the
featured. The complement of speakers will • Contribution to Skills & Training Award – presentation ceremony, the promotional benefit
share their knowledge and expertise in a series Sulzer is even greater.

6 | Plant & Works Engineering www.pwemag.co.uk August/September 2023

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News

Young engineers get tooled up

Electromechanical repair specialist, Fletcher Moorland will randomly draw from the entrants
Moorland, has launched an initiative to support and notify the lucky winners. Anyone who
the younger generation entering engineering, wants to nominate a young person to be
design, and manufacturing careers. entered can also do so by tagging or, if they
Under the banner Get Tooled Up, Fletcher aren’t on LinkedIn, nominating them on the post
Moorland is giving away five sets of quality featuring the hashtag.
tools to young apprentices and aspiring Initially, Fletcher Moorland funded the prize
engineers every month. Since its launch, the tools itself, but for the latest draw, the initiative
initiative has seen the company give away tools has drawn support from DIY-repair specialist
including infrared thermometers, VDE pliers and iFixit, which has donated five of its ProTech tool
hex key sets, from Fluke, RS components and kits as the prizes for the May draw.
Wera, to young engineers from across the UK. “I absolutely love iFixit,” said Matt. “Its
Commenting on the initiative, Matt Fletcher, mission is ‘To teach everyone to fix everything.
Managing Director at Fletcher Moorland, said: Let’s fix the world together,’ which is a great fit
“Tools cost a lot of money; ask any engineer. for what we are doing. Many young engineers
It’s particularly hard when starting out in an start out by taking things apart to see how they
engineering career. You want the best tools to work and see if they can fix them. With its tools
do your job but to get good quality equipment and its repair tutorials, iFixit is making this
does cost money. possible.” story to tell.”
“I want to put decent tools in the hands of The following month, global industrial and Any tool supply companies looking to
apprentices and young engineers from the start, mechanical tool brand, Beta, is donating the support the initiative are invited to contact Matt
and I’m committing to do this.” prizes, and Matt believes there is an excellent Fletcher directly. And any young or inspiring
For young engineers to be in with a chance opportunity for other suppliers to support the engineers, or their colleagues, friends, and
of winning tools that could help them as they initiative: “Brand loyalty is a powerful thing and family, to enter, simply look out for the hashtag
embark on their careers, all they have to do is getting tools into the hands of engineers at the #GetTooledUp.
look out for posts on LinkedIn carrying the beginning of their careers could see lifelong
#GetTooledUp hashtag and then comment or customers born. Plus, from a marketing point of For further information please visit:
hit the like button. Each month Fletcher view, supporting young engineers is a great www.fletchermoorland.co.uk

M&E Week becomes industrial sector’s biggest event

Manufacturing & Engineering Week 2023 has become the biggest
industrial sector event in the UK in just its second year, according to
statistics released by event organisers The Nineteen Group. Over the
course of the live shows on the 7 and 8 June, 10,355 manufacturers,
designers, engineers and maintenance professionals attended the event
at the NEC which had 342 exhibitors.
Senior manufacturing leaders attended the Manufacturing Digitalisation
Summit and the SME Growth Summit, while also finding time to visit the
Google Leaders’ Lounge. As part of the STEM programme more than
450 students attended the exhibition on the final afternoon finding much
to inspire them in the Made Smarter Innovation Alley, the Innovation
Village and beyond.
Haf Cennydd, Portfolio Director for Manufacturing & Engineering
Week said: “To have built the biggest UK event for the industrial sector in
just two years has surpassed our expectations and clearly demonstrates sustainability discussed in detail. It was great to see the show also offset
that bringing together Smart Factory Expo, Design & Engineering Expo their carbon emissions once again by planting thousands more trees in
and Maintec was a great idea. With industrial events also taking place at the M&E Week Forest.”
the same time and venue run by other event organisers plus the addition Maintec in particular has benefited from its inclusion in M&E Week
of Drives & Controls, Air-Tech and Fluid Power & Systems, there will only with Chris Hansford of Hansford Sensors commenting: “I have been
be more to see and do in 2024.” coming to Maintec for 36 years and this is the busiest one I can
Manufacturing & Engineering Week has the support of most of the remember. The event has had a shot in the arm which is great for our
high-profile organisations, institutions and trade bodies representing the business and the maintenance sector as a whole.”
UK’s industrial and manufacturing sector, none more so than Make UK. Engineers Without Borders UK, the official charity partner for
Stephen Phipson CBE, CEO of MAKE UK and chair of Manufacturing & Manufacturing & Engineering Week, used its presence as an opportunity
Engineering Week said of this year’s event: “Manufacturing and to launch a global responsibility competency compass to address the
Engineering Week has gone from strength to strength from last year to this sustainability skills gap in engineering. John Kraus, CEO said: “The event
year and we expect it to grow even further next year. Key challenges has given the whole team a boost. It’s given us a platform for our launch
were high on the agenda for the second year with skills, supply chain and and an opportunity to network directly with people working in industry

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News

and their representative bodies. Our ambitions and those of Nineteen the sheer sense of excitement generated on the exhibition floor it’s been
Group align in that we wish to ensure that responsible engineering superb, and it will only get better next year as we add Drives & Controls,
principles are being embedded at every level and that decisions made Air-Tech and Fluid Power & Systems into the mix.”
balance the needs of all people with the limits of our planet.” Dates for the live events for M&E Week in 2024 have been confirmed
Peter Jones, CEO of Nineteen Group commented on the success of the as 5-6 June for Smart Factory Expo, Design & Engineering Expo and
event: “We gave our team the licence to disrupt the accepted norms of Maintec (2 days, Hall 4) and 4-6 June for Drives & Controls, Air-Tech and
what an industrial sector trade show looked like, felt like and achieved Fluid Power & Systems (3 Days, Hall 5).
and they have over-performed by every measure. From the Nexa3D
guitar players’ competition to the festival-like stilt walkers and branding to For more information visit: www.mandeweek.co.uk

PPMA Show set to showcase latest developments in

the UK’s processing and packaging industry
The processing and packaging machinery demonstrations, source new ideas and with the latest and greatest technologies.
exhibition, PPMA, will once again take place solutions, and meet with potential new Some of the companies exhibiting include
at the NEC Birmingham, between 26-28 suppliers and technical experts. Advanced Conveyor Group, BrilloPak,
September. This is a complete production line Richard Little, the PPMA Show Director Clearview Imaging, Excel Packing Machinery,
event with something for everyone involved in commented: “Between the 350+ companies IDEM SAFETY Switches, Lafert Electric Motors,
processing and packaging machinery, robotics exhibiting there are thousands of years of Mil-Tek UK Recycling & Waste Solutions,
and industrial vision systems. experience in packaging, processing and Premier Labellers, and Westrock Packaging
The show will be a representation of this automation machinery. Visitors are Machinery & Automation.
fast-growing industry, featuring food, encouraged to bring their problems and This is a rapidly growing industry with
beverage, pharmaceuticals, household requirements to the show. There will be people immense potential with exciting new products
products and toiletries, building materials and in the show who know what to do and there and technologies are being developed all the
supplies, pet care, micro-brewery and will be plenty of machines to look at actually time; an industry that is constantly innovating
distilleries, FMCG, as well as contract packers doing it.” and evolving.
and more. The best and brightest businesses of this
Visitors will be able to take advantage of industry will be eager to demonstrate to For more information:
the networking opportunities, live visitors how they can improve their businesses https://www.ppmashow.co.uk/visit

MAKE uk - the manufacturers’ organisation monthly news comment

London and the South East, Wales and Northern Ireland also saw
increases in the number of manufacturing jobs.
The report also highlights the importance of manufacturing and jobs
to so-called ‘red wall’ areas where the sector occupies a substantially
higher than average contribution to the regional economy. The average
regional share of manufacturing nationally in the UK (2) is just under
By MAKE UK chief executive,
10% (9.8%), whereas in Wales the sector accounts for almost a fifth of
Stephen Phipson
the economy (17.3%), whilst it is also substantially above the average as
Every year Make UK publishes an analysis of official data which looks a share of the economy in the East Midlands (16.4%), Yorkshire &
at the contribution of manufacturing to each English region and the Humber (15.4%), North East (15%), West Midlands (14.4%) and the
devolved nations. The analysis looks at metrics such as employment, North West (14%).
sectoral composition, output and export destinations of each region’s The second striking factor was how most English regions and Wales
goods. This year there were two striking factors. Firstly, in 2022 are seeing a downward trend in their share of exports going to the EU,
compared to 2021 the number of jobs in manufacturing has grown in suggesting a possible shift in trade patterns. While the overall share of
six of eight English regions along with Wales and Northern Ireland. This UK goods exports going to the EU increased in 2022 from 2021
is very unusual given employment levels have been stable, or in slight (52% compared to 50%) this was largely boosted by
decline, for some time and counter the long-held narrative of inevitable substantial increases in the share of exports going to
decline in manufacturing employment. They also show, as is happening the EU from both Scotland Northern Ireland.
in the US, that growing manufacturing jobs and the sector’s share of the Without these increases it’s likely that the UK’s
economy is a realistic prospect given a supportive policy framework. overall share would also have fallen significantly.
Yorkshire & Humber saw the biggest growth in manufacturing jobs, There may be a number of factors at play to
adding 46,000 jobs in 2022 compared to 2021, bringing the total explain this shift but if the trend continues then there
number to 316,000, more than one in ten (11%) of the region’s are implications for Government policies to support
workforce. exporters with a shit in emphasis needed to
The South West saw the second highest increase, closely followed support companies exploring markets outside
by the East of England. The East and West Midlands, together with the EU.

08 | Plant & Works Engineering www.pwemag.co.uk August/September 2023

 Thanks to Mewa industrial
cleaning wipes, the environment
is becoming a little cleaner.
Mewa
09_pwe_0823.indd 1
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17.06.23 15:22
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Insight Talking Industry Review

Talking Industry
Digital technologies
in maintenance
The latest Talking Industry (TI) panel discussion discussed how digital technologies can be
used in maintenance activities. What can you learn from machines using digital techniques,
such as machine learning and artificial intelligence (AI)? TI Chair, Andy Pye reports.

M
any companies are still not making the most of the a growth of preventive maintenance. This led to an increased asset
opportunity to provide insight into machines by reliability, lower cost of ownership and - particularly important in the civil
monitoring critical components that are subject to wear aerospace - a reduction in aeroplanes falling out of the sky! Then
and tear. followed the third generation of maintenance: a real understanding of
Richard Jeffers got proceedings underway by explaining that one of his
favourite topics is the digitisation of maintenance. Maintenance is the
process of keeping plants and equipment in good working condition, so Panelists
that efficiency is retained and/or the life of that asset is increased. 䡲 John Erkoyuncu, Professor of Digital Engineering and Head of
Maintenance, he argued is not actually that complicated. But it is really the Centre for Digital Engineering and Manufacturing at
hard work to get it right every day consistently. Cranfield University
The first generation was very much reactive, time-based maintenance.
There was really no underpinning understanding of reliability theory of 䡲 Richard Jeffers, Founder & Managing Director, RS Industria
why components failed. And then in the 50s, 60s and early 70s. we
moved into the second generation of maintenance. Driven by civil 䡲 Dave Roddis, Senior Advisor - Digital Transformation, The MTC
aerospace, there was an emerging understanding of reliability theory and

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Talking Industry Review Insight

long to put into practice? What do we need to do to get these

techniques more widely adopted?
Richard Jeffers answered that the falling cost of technology makes it
easier to deploy in lower criticality environments. What we see now is
technology that was traditionally only available in in the aerospace
industry or high value fleet operations, now being able to be moved into
broader manufacturing environments. What really underpins the whole
world of condition monitoring is that understanding of how components
fail. Only 10 to 25% of components fail for time-related use - the other 75
to 90% fail for random reasons. And so condition monitoring and
predictive maintenance is all about identifying and measuring a leading
indicator of that random failure in a cost-effective and reliable way.
David Roddis emphasised that an obvious factor is education. Business
leaders really need to start to understand the benefits of the digital age. If
you are not bringing and using digital tools, you will start to fall behind
your competition.
John Erkoyuncu concurred that skills development is key, looking at this
in a strategic way from leadership to mid-management level to those may
be coming into the organisations. How do we develop the ability to make
decisions from a “digital 4.0 perspective”? Something that we need to
focus on is the continuous transformation of businesses, going beyond the
ad hoc introduction of technologies, and developing a culture where you
are embracing new technologies coming into the organisation.
reliability theory and how and why components fail, which led to the I asked Erkoyuncu how, in training young engineers, he keeps up to
growing use of condition-based and predictive maintenance. Now, date with fast-moving technological developments. How does he keep
Maintenance 4.0 is the fourth generation of maintenance, the students up to date? And conversely, how can you influence the culture in
digitalisation of this process. a in senior managerial environments?
I asked why, if the basic theory goes back to 1968, why has it taken so Erkoyuncu replied that Cranfield is a wholly postgraduate University,
very much focused on working closely with industry. As an example, there
is an MSc course called digital and technology solutions, which was
Reliability theory and the digital mindset developed with over two thousand companies that actually shared the
Pye: “One of the perhaps unwarranted criticisms of academia in kinds of skills requirements that they have.
fast moving technology areas is how they keep up with
developments in technology. And then you have the issue of * Talking Industry is sponsored by the Drives & Controls
standards lagging behind. These difficulties are in the Exhibition, the #1 event for automation, power transmission & motion
background, impeding the implementation of something as new as control. Taking place 4-6 June 2024, at the NEC, Birmingham. In
industry 4.0.” association with Manufacturing & Engineering Week 2024. Drive
The Future. www.drives-expo.com
Erkoyuncu: “It is hugely challenging. And I think the key thing here
is that we continue to communicate, to ensure that we are not
stuck in what’s available today. We need to solve today’s Talking Points - the true cost of downtime
challenges, but we also need to be a step ahead.” It’s often thought that you need to plaster your machine with
sensors to get any useful information out of it, but it is often not as
Roddis: “Although we are talking about maintenance, when you complicated as that: much essential data can all be accessed via
are capturing data, you want to think about how to use that data a simple PLC.
throughout the business, not maintenance of the machinery, but To help maintenance teams work cost-effectively, it is important
utilisation as well. We call this the ‘digital mindset’”. to have a view of an entire plant helping maintenance teams
work easily and cost-effectively.
Jeffers: “For me, there is still an over-reliance on time-based Richard Jeffers cited some work with the IMechE based on 700
maintenance in most factories that I visit, with people not returns from engineers within the UK. And we asked about the
understanding the failure modes that are impacting the assets, average cost of downtime and the amount of unplanned
therefore using maintenance approaches that are actually going downtime that’s experienced so and that came back with the
to induce early life failure rather than, you know, predict a average unplanned downtime was 20 hours a week. And the
random failure event. I agree completely with the points that John average cost of downtime was £5000/hr. So that’s
and David made around education around digital, but I think £100,000/week or £5 million/yr. If you are operating at a
you’ve got to underpin that with education around reliability margin of 10% return on sales, you’ve got to make £50 million
theory as well, because otherwise, you risk digitising something worth of incremental sales to recover the lost impact of that
you don’t understand!” downtime.
The conversation continued.... listen to the on-demand version of
this Talking Industry episode to hear more the panelists’ To read the IMechE/RS ‘Industry in Motion’ survey please visit:
comments, together with answers to the attendees’ questions. https://uk.rs-online.com/web/content/m/industry-in-motion

August/September 2023 www.pwemag.co.uk Plant & Works Engineering | 11

12-13_pwe_0923.qxp_Layout 1 07/08/2023 10:07 Page 12

Maintenance Matters Focus on: Plant & Asset Management

How EAM software

helps reduce costs
Optimal utilsation of assets, low downtime and low maintenance costs ensure the highest
possible productivity. This requires an intelligent EAM solution for registering and analysing
the data.

T
hose who work efficiently and with the greatest possible cost- may depend. Good reasons to treat the topic with high priority. Properly
effectiveness gain advantages on the market - whether in maintained machines and equipment save costs through maximum service
mechanical engineering and the automotive industry, in the life without unexpected failures, through a long service life of the
chemical and food industries, or in logistics. Optimal utilisation of individual components and through high energy efficiency. At the same
machines with as little downtime as possible is the key to success - time, they ensure consistent, high product quality and little waste.
combined with strict cost control. What sounds plausible in theory is
complex in practice. In the recently released Enterprise Asset Management Service life and maintenance costs in balance
(EAM) Trend Report 2022 by IFS Ultimo, companies name uptime Working economically also means knowing the costs of the necessary
(33.73%), efficiency (30.47%) and cost control (19.53%) as the most maintenance and upkeep and putting them in a reasonable relation to
important KPIs for asset managers across all sectors. At the same time, the productivity increases and costs for downtime. Maintenance costs include
vast majority of survey participants (82.17%) were unable to quantify how time, labour and costs for personnel, as well as for spare parts and
much downtime costs their company per hour. Additionally, 60.45% of the materials and their procurement. In addition, when deciding on a
asset managers surveyed had experienced unplanned downtime in the measure, consideration should be given to whether a small additional
past year. What was the cost of this downtime - and what measure would expense can significantly extend the expected service life of the
have prevented or reduced this downtime, and at what cost? Those who equipment and whether the benefit is justified at all. Apart from efficiency
know these figures make them transparently available in the company and of maintenance and repair work, the provision of labour and spare parts
use them as a basis for maintenance and repair decisions, saving on costs must also be considered from an economic point of view.
and thus increasing their productivity and profitability. If you know all these costs, you can identify cost drivers or inefficient
measures and make informed decisions that can reduce costs sustainably.
Know and minimise the costs of downtime
The aim is therefore to keep machinery and equipment in optimum Which is less expensive - Predictive maintenance Vs repairs?
condition and thus production up and running. This also ensures timely Once there is clarity about the concrete costs, plant operators can weigh
delivery to the customer, on which follow-up orders and market image up which cost benefits can be exploited through predictive maintenance,

12 | Plant & Works Engineering www.pwemag.co.uk August/September 2023

12-13_pwe_0923.qxp_Layout 1 07/08/2023 09:56 Page 13

Focus on: Plant & Asset Management Maintenance Matters

which then predicts the best time for the precautionary replacement of costs to maintain their assets, what the cost of downtime is compared to,
equipment parts and thus makes maintenance plannable and minimizes and what impact the change in maintenance method has on availability
downtimes. The big boom for Industry-4.0-solutions, networked and productivity. For this purpose, it is necessary to systematically collect
equipment and digital twins is proof that there is great potential here for and analyse the data and prepare it and make it accessible to the
increasing efficiency and effectiveness. The IFS Ultimo trend report stakeholders involved in the company - from the user to the maintenance
mentioned at the beginning of this article also shows that companies are manager to controlling and management.
clearly willing to invest in technologies that have a positive impact on
cost control and uptime of their assets. 48.15% - almost half of the Digital twins bring equipment online
companies - identify investments in IT and IoT solutions as the top solution The IFS Ultimo EAM system enables the digital management of machines
for this. and equipment throughout their entire lifecycle and includes the planning,
Not only can companies decide between proactive maintenance and optimisation, execution and documentation of maintenance activities.
repair when they know the cost of each item and the impact on the life of The cloud-based IFS Ultimo EAM platform collects the relevant data
their assets, but with comprehensive data, it is also possible to decide centrally so that it is available in one place, even if a company has
who will ideally implement measures: an on-site technician, who multiple sites and production facilities. Everyone involved in the processes
admittedly also costs money on the one hand and may have to be accesses the same data - whether on PC, tablet or smartphone.
trained, or a specialist, who in case of doubt will only be on site with Beyond retrieving equipment data, it is possible to use virtual and
some lead time and thus possibly extend the downtime. In order to augmented reality (VR and AR) to create digital twins of a machine on the
achieve maximum efficiency, it is essential to find optimum solutions here - network and share current views from on-site with a remote working
right through to the implementation of measures by the user under the expert. These technologies are seamlessly integrated into the IFS Ultimo
guidance of a service technician. EAM system and open up new possibilities for collaboration and
maintenance management for companies. This also saves time and costs
Sustainable cost control made easy for maintenance.
So, it turns out that identifying costs, controlling them and managing the IFS Ultimo can, according to the company, also integrate other
corresponding expenses is the key to achieving the highest possible corporate data - for Health, Safety and Environment Management, for
production efficiency and profitability. Once this information is available, example - and link to other software solutions such as business
the challenge is to ensure seamless documentation and communication intelligence tools. This creates an extensive ‘big data’ platform for data-
within a company. Only then will asset managers know what it actually driven business decisions.

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August/September 2023 www.pwemag.co.uk Plant & Works Engineering | 13

14-15_pwe_0923.qxp_Layout 1 07/08/2023 10:58 Page 14

Maintenance Matters Focus on: Preventive/Predictive Maintenance

Marine equipment:
How predictive maintenance
can detect defects before
mechanical failures
Reducing downtime owing to machine faults and breakdowns is important for all industries,
but with marine equipment typically being in a remote location, how do we react when
problems occur? Steve Ellis Managing Director at FPE Seals explains further.

P
redictive maintenance, where data older machinery or machinery that is critical to last minute when something goes wrong. With
analysis is used to detect potential the output of the company. travel from engineers often over large distances
defects before a mechanical failure involving air travel, downtime can be lengthy
occurs, is the way forward. Here, we Reduces downtime and be very costly to the business.
take a deep dive on how it works - and how it Downtime in any industry is costly to the bottom
can be of benefit to the marine industry. line while there is a wait for repairs to be Remote condition monitoring reduces travel
The overall aim of predictive maintenance is completed or a replacement to arrive, not to and time costs
to pinpoint potential faults in machinery at the mention any further time required for installation Using predictive maintenance will enable the
earliest opportunity, with the goal of removing and training on the new machinery. scheduling of corrective maintenance when it is
the need for more complex maintenance, The importance of reducing downtime is easier for it to take place. Having a way of
repairs and even replacement. particularly prevalent in the marine industry due predicting a failure on board a ship ensures that
Monitoring tactics allow potential failures to to the locations machinery is located in. Remote repairs or replacement parts can be installed
be spotted, and the part repaired or replaced locations in the marine industry can often make before the vessel reaches open water - where it
before a full breakdown occurs. Predictive repairs time-consuming and costly. would be significantly more difficult.
maintenance is more effective and efficient By having predictive maintenance in place, This saves time, money and impacts on the
when used to monitor machinery or equipment engineers can plan and replace anything health and safety of the workforce on board, as
that is more prone to breakdown. For example, effectively, rather than be forced to react at the they are not entering operations with a

14 | Plant & Works Engineering www.pwemag.co.uk August/September 2023

14-15_pwe_0923.qxp_Layout 1 07/08/2023 11:26 Page 15

Focus on: Preventive/Predictive Maintenance Maintenance Matters

potentially faulty machine or piece of cause problems that were literally impossible to are all important things to note.
equipment. Replacing valves, cylinders, or predict or make contingency plans for. When you add to this the significance of
integral parts such as hydraulic cylinder Despite this, the ability to foresee problems reduced downtime and even the impact on the
parts needs to be conducted as efficiently as and solve them before they become a huge health and safety of employees, we see how
possible. issue is one that certainly improves business predictive maintenance can benefit the marine
efficiency. industry.
More efficient way of working Sources
Generally, predictive maintenance enables a In conclusion 3 Benefits of Predictive Maintenance In The Marine Industry
more efficient way of working. Avoiding last- As with any industry, being able to predict (sensonics.co.uk)
minute changes because of breakdowns is just when things may go wrong of breakdown can Predictive Maintenance for Marine Vessels (marine-
a better way for an organisation to operate. only be a positive thing. digital.com)
Of course, not everything is predictable - the The remoteness of some of the equipment,
nature of the marine industry means that the difficulty of access to some locations and For further information please visit:
extreme, unforeseen weather can occur and the expense of last-minute reactive maintenance www.fpeseals.com

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August/September 2023 www.pwemag.co.uk Plant & Works Engineering | 15

16-17_pwe_0923.qxp_Layout 1 09/08/2023 10:22 Page 16

Maintenance Matters Focus on: CMMS

Achieving control
& effective asset
maintenance
The ability to have a clear view of all assets and maintenance to drive effective
management and control is still a huge challenge. PWE takes a look at how Wienerberger
has achieved this with the support of the Agility CMMS solution from SSG Insight.

T
he pursuit of complete control and changer for the company, providing them with the company has gained better control over its
efficient asset maintenance remains a a unified platform to manage their assets and maintenance team’s activities and time
major challenge for many industries. generate actionable reports. management. Additionally, the comprehensive
However, Wienerberger has found a SSG Insight, a prominent player in the reporting capabilities offered by Agility have
solution to this predicament through the support CMMS realm, has always been committed to vastly improved decision-making processes.
of the Agility CMMS solution from SSG Insight. supporting its customers in achieving control Back in 2016, Wienerberger’s team faced
In this editorial, we delve into Wienerberger’s over assets and maintenance to enable the ever-increasing challenge of how to
journey with Agility, highlighting the effective maintenance management. Its Agility manage its maintenance and assets more
transformative power of this technology in solution has evolved over the years to cater to effectively. Ben Henda, explained: “Before
driving effective maintenance management. the evolving demands and technological Agility, we had no clear picture of what was
Ali Ben Henda, the Continuous Improvement advancements of its extensive client base, happening across our 14 sites, and we didn’t
Manager at Wienerberger, eloquently ranging from SMEs to massive global have a ‘one source of truth’ when it came to
encapsulated the significance of Agility: “If I enterprises. managing assets. Maintenance was delivered
had to describe using Agility in a nutshell, for Wienerberger, a long-term user of Agility, on a case-by-case basis and not collated
me, it is pivotal that all our data is in one place has harnessed the power of this CMMS to across our 14 manufacturing operations. Agility
and that we have visibility of the reports...” This achieve unprecedented control over its assets. was particularly attractive to us as it
singular feature has proven to be a game- By leveraging targeted maintenance practices, standardized the way we were doing things,
allowing us to make data-driven decisions on
our maintenance team’s timetable.”
With the introduction of Agility,
Wienerberger experienced significant
improvements. The solution standardised
I
maintenance practices, empowering them to
o
make informed decisions based on data-driven
H
insights and enhancing productivity across all 1
14 manufacturing operations.
The success of Agility at Wienerberger is #
evident from the statistics: 7500 assets listed,
4055 PPMs (Preventative Planned
Maintenance), and over 320 user accounts,
70% of which have embraced Agility Mobile.
P
Ali Ben Henda continued to explain: “Once
1
we introduced Agility, we were able to start
gathering our data in a more consistent and
cohesive way and we were able to better
manage our asset maintenance timetable.
“Agility is designed for many different
businesses across lots of different sectors
however, it is not rigid, and the company didn’t A
need to change lots of its processes to fit Agility,
Agility was and is flexible enough to meet with
our specific requirements. T
“I can see everything from the Work Order
List to the Equipment Structure, to Job Analysis

16 | Plant & Works Engineering www.pwemag.co.uk August/September 2023

16-17_pwe_0923.qxp_Layout 1 09/08/2023 10:22 Page 17

Focus on: CMMS Maintenance Matters

(completion, open, etc.), to Labour Utilisation, its pivotal role as a unified data repository, SSG Insight team is really strong: “We work
Priority Codes, Shift Logs, Checklists, and more. offering unparalleled visibility through closely with our account manager, but
The way Agility has pulled all this information comprehensive reports, including maintenance we also know the team in product, support,
together for us and centralised it is now vital to time control, job completion by job type, the tech consultants, and many others,
our business and makes life so much easier outstanding work orders by priority and by as well.”
when it comes to reporting.” overdue timescale, jobs raised, jobs by craft, In addition to the support, Ben Henda said
He continues to highlight that to simplify its and of course maintenance against the that his company has found tremendous value
maintenance procedures, the company company’s KPIs. He highlights that “it’s all there in the training and monthly webinars offered by
embraced Agility’s checklists for all Preventative in visual dashboards that I can easily share with SSG Insight. These resources have illuminated
Planned Maintenance tasks, while introducing others so that we can all understand what’s various aspects of the software, enriching it use
mobile phones empowered its teams to access going on.” and fostering a strong sense of teamwork
crucial information on the go, significantly Ben Henda commented that throughout this across different sites.
helping real-time job completions with transformative journey, the support of the SSG Ali Ben Henda concluded by stating that as
comments and photographs. Admin tasks were Insight team was instrumental. The culture of the company treads further on its Agility journey,
also no longer an issue, with realistic timescales innovation and constant exploration of new the company envisioned a future of possibilities:
as to how quickly jobs are being completed. technologies resonated deeply with the “We’re working with our Account Manager
Ben Henda adds that the company’s drive company: “Their regular visits to our operations, and having some great conversations about the
for continuous improvement led it to integrate a witnessing Agility in action and understanding art of the possible in terms of connecting
Criticality Factor based on the Failure Mode, our unique methodologies, showcased a true through the API, taking our internal systems, and
Effects, and Critical Analysis (FMECA) matrix, partnership focused on maximising our software connecting them to Agility, and what this could
following PIP+ guidance. Additionally, the utilisation and adapting it to our future needs.” mean.
company harnessed QR codes using Functional Notably, he explained that the “With Agility, we have better control over our
LOCation (FLOC) numbers and seamlessly responsiveness of the support team offering assets, more targeted maintenance, better
integrated Meerkat Continuous Monitoring timely assistance whenever required. Sharing management of the maintenance team and
sensors through a custom API, elevating the support responses across teams further their time, and more effective reporting.”
capabilities of the system to meet its unique promoted a unified and informed approach to
demands. challenges. For further information please visit:
For Ben Henda, Agility’s greatest asset lies in He continued that its relationship with the www.ssginsight.com

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18_pwe_0923.qxp_Layout 1 07/08/2023 09:54 Page 18

Maintenance Matters Problem Solver

Cloud-based SCADA for asset monitoring

Environmental Monitoring Solutions (EMS), a provider of energy management systems to
water suppliers, asked Ovarro to assist in improving the way data is presented to its clients?
PWE reports.

F
or years, Environmental Monitoring Solutions (EMS) has relied information. Due to its modern modular design, Stream Webscada is easy
on Ovarro’s TBox remote telemetry units (RTUs) and other systems to connect to various third-party systems, with fast response times.
throughout its networks that provide energy management systems to Assets in critical infrastructure networks ? including water ? often run
water suppliers. The challenge that EMS has is that each industrial unsupervised in remote locations. Effectively monitoring and controlling
water customer has different network requirements, key performance these assets 24/7 is a challenge for operators in any industry. This can
indicators (KPIs) and uses a variety of different Internet of Things (IoT) lead to non-proactive maintenance, with costly and unexpected recurring
systems. failure replacements.
EMS approached Ovarro to assist in improving the way data is As a solution, the Stream Webscada platform gives Ovarro’s customers
presented to their clients, simply add new clients to its networks, support real-time insights into processes and asset health, and the ability to control
existing customers more efficiently, offer its own apps to new customers, connected field equipment.
and extend its network. “Stream Webscada gives us two-way communications, alarms, updated
For a solution, EMS has chosen Stream Webscada from Ovarro. The calibration information and more, 24/7,” said Gary Thursfield, Technical
scalable and modern 4G web-enabled SCADA platform gives customers Director, EMS. “The platform can streamline how we manage and collate
real-time insights into processes and asset health, and the ability to control information on all our customers.”
connected field equipment.
Stream Webscada is accessed through various devices, like iPads, with
secure log-ins and cybersecurity backed by Amazon web services and
Microsoft Azure.
Projects can be tested and developed offline before going live, and
metrics are used to monitor and control connected field equipment such as
TBox RTUs and Ovarro’s D26 series wireless data loggers, programmable
logic controllers (PLCs) and IoT-devices.
With Stream Webscada, EMS can improve the way data is presented
to its clients. Ovarro continues to support the customer’s use of the platform.
The Stream Webscada platform is suitable for managing and controlling
different assets and geographically spread processes, combined
with telemetry systems that are easy to use and offer 24/7 online process

Advancing monitoring and diagnostics

M
onitoring the condition of large a reduction in equipment fleet operating costs, or
industrial equipment fleets is total cost of ownership, by enhancing condition
challenging and, without the monitoring and understanding faults early.
necessary insights, it can be Marek Lukaszczyk, European & Middle East
hard to understand the health and performance marketing manager at WEG, explained:
of assets. To help operators overcome this “Detecting faults in industrial equipment is one
challenge, industrial digital solutions provider thing, but communicating effectively to
WEG has launched its new WEGscan sensor. understand their impact is another.” He added:
By integrating WEGscan into their fleet, “WEGscan is the cutting edge of condition
operators can monitor a wide range of monitoring technology, harnessing the cloud,
equipment, including reducers, gear motors and IoT and AI to provide operators with all the
compressors, helping operators reduce costs information they need to maintain uptime and
and improve predictive maintenance. avoid costly asset breakdowns.”
The new sensor is an evolution of the existing industrial sectors. “This latest addition builds on the benefits of
WEG Motor Scan WEGscan and can be WEGscan can be customised for virtually the WEG Motor Scan, and goes further by
integrated onto a range of industrial assets to any asset, and its communication range and monitoring the operational status of everything
gather data and feed it to WEG Motion Fleet capability is far more evolved than previous from gear motors, pumps and exhaust fans to
Management (MFM), a condition-based products. compressors and reducers. The scope of
internet of things (IoT) platform that allows The new sensor offers a cloud solution, with monitoring is greater than ever, making it easier
customers to monitor their assets online. Using WEG MFM facilitating data storage, analyses for businesses to make vital operational savings
this technology, users can monitor the by a technician or specialist, and data and prevent unplanned downtime.”
operational status of electric motors, processing using AI for autonomous fault
compressors, fans, planetary reducers and diagnosis. Therefore, by combining WEGscan For further information please visit:
many other assets on sites across different with the platform, businesses can be benefit from www.weg.net

18 | Plant & Works Engineering www.pwemag.co.uk August/September 2023

 Optimise your assets & maintenance
Maintenance teams continually strive to prevent breakdowns, failures and
downtime. Agility CMMS works to pre-empt and reduce asset or equipment
failure, ensuring that routine and predictive maintenance runs smoothly.

Agility CMMS enables

maintenance teams to:
• Proactively reduce downtime
• Simply generate work orders
• Easily assign the right staff for the job
• Effectively schedule predictive
maintenance
• Ensure parts are in stock
• Maximise labour usage
• Decrease work order backlog
• Monitor trends & asset lifecycles
• Quickly produce asset & maintenance reports

“We’ve been able to effectively analyse breakdown

time which has had a huge impact on our operations,
the real-time view we have within Agility has
allowed us to predict and establish potential issues,
significantly decreasing breakdowns, saving us
valuable time and money.”
Matt Shakespeare, ZND Maintenance Manager

Take a look at Agility and see what it could offer your

maintenance team and your business, call 01924 200344 today.

Visit www.ssginsight.com Email enquiries@ssginsight.com

Formed in 1983, SSG Insight focus on the people we work with to constantly
innovate and deliver outcomes for smart workplace ecosystems.

19_pwe_0923.indd 1 01/08/2023 10:29

20-22_pwe_0923.qxp_Layout 1 08/08/2023 14:12 Page 20

Process, Controls & Plant Focus on: Compressed Air

Prioritising energy
performance when designing
a compressed air system
Cliff Warne, BCAS Executive Director explores the importance of compressed air system
design to ensure energy performance is optimised, highlighting the various options
available to calculate the annual running cost of an air compressor, while also advising
on how best to design an energy-saving system.
downstream and air treatment equipment,
pipework and storage.
Focusing on just one area of the system at
the expense of others, will mean that other
opportunities to save energy could be missed,
leading to unnecessary energy usage.

Designing an energy-saving system

With air compression accounting for as much
as 10% of all the electricity consumed by
industry, the air compressor could be one of the
largest energy-consuming systems in the plant.
But it’s also important to consider that the usage
and design of the system will dictate its overall
energy consumption.
Poor system design, incorrectly dimensioned
distribution piping and air treatment
(purification) equipment can lead to avoidable
pressure loss, so it’s important to factor these
areas into the overall system design.
Effective maintenance also has a key part to
play in overall system efficiency. For example,
just one 2mm hole in the pipework, could cost
over £1,249 per year in wasted energy, so
implementing a regime for regularly inspecting,
and remedying can help lower operating costs.
A high leak rate can also cause fluctuations
in pressure, resulting in hidden costs such as

I
n April last year, the British Compressed report entitled ‘Compressed Air Systems in the slower running or even production downtime,
Air Society (BCAS) launched the 10% European Union’1, when looking at the most not to mention a noisy environment for staff.
Taskforce - a call for UK businesses to take important energy savings techniques available Regularly maintaining any ancillary
simple steps to cut their compressed air to compressed air users, ‘the energy savings equipment including dryers, filters, and air
energy usage figure by 10%. amount to 32.9 per cent, achievable over a 15- receivers is also important, alongside checking
The campaign has an ambitious target to year period.’ inlet filters routinely, and replacing where
save over 411 thousand tonnes of CO2, the Therefore, since the launch, BCAS members required, before the pressure drop across them
equivalent of taking 317 thousand cars off the have been speaking with customers to becomes significant.
road. encourage them to act and realise savings now.
When BCAS launched the campaign, no Calculating the system’s annual cost
one could have predicted the scale of the rise Take a 360 approach Before embarking on any compressed air
in wholesale gas and electricity prices. The When operators invest in new plant and system upgrade to help maximise energy
campaign’s original calculations of £485.43 equipment there can be a tendency to focus on savings, it is important to calculate the system’s
million being spent in wasted electricity have the compressor itself, without considering the total yearly cost.
now risen two or even three-fold. complete compressed air system and its impact
Generating compressed air can be very on energy consumption. However, it is Option 1
energy intensive, representing as much as 30% important to consider all areas of the air supply To calculate the electrical consumption of the
of a site’s total electricity bill. According to a – not only the point of generation, but compressor, operators will need to obtain the

20 | Plant & Works Engineering www.pwemag.co.uk August/September 2023

HI-Line_new.qxp_29_H&P_0308 08/08/2023 09:39 Page 1

  
  

   
Green Street, Burton-Upon-Trent, Staffordshire DE14 3RT
Tel: 01283 533 377
+%): "-1:6 &::2 %"4$&:)':- "&:. !:6 453("4 /,
777$&*&-"&-!6453&"4 /+ : 9 



  
    

20-22_pwe_0923.qxp_Layout 1 08/08/2023 14:12 Page 22

Process, Controls & Plant Focus on: Compressed Air

reading by sub-metering the compressor house. Cliff Warne, ownership in the long term.
BCAS Executive
This will be in kilowatt hours (kWh). Director There are many straightforward ways to save
energy consumption from compressed air
Option 2 systems and, implementing just one or two of
A data logging system will also help to the steps highlighted above can help minimise
determine the yearly cost of the compressor avoidable waste significantly.
system. This needs to be installed for a period In doing so, industry can make considerable
of at least seven days. overhead, and carbon footprint savings
With this system in place, the pattern of alongside a significant contribution to bottom
demand can be established, otherwise known line profitability and environmental
as a demand profile, and the off-load running performance.
time when there is no demand for air. This does
not account for the ‘off-load’ power For more information, please speak to a
consumption when the compressor is BCAS member who can assist in this area by
consuming energy without generating air. emailing enquiries@bcas.org.uk
costs £0.1249/kWh, the annual energy cost
1
Option 3 is £14,988. Should production time increase Compressed Air Systems in the European
And finally, option three allows plant engineers to 6,000 hours per year, for example, then the Union. Energy, Emissions, Savings Potential
to calculate the annual cost of the system by annual energy cost would rise to £44,964. and Policy Actions. Peter Radgen and Edgar
estimating the energy consumption of each air With a range of options available to Blaustein (Editors: Note that the potential
compressor. monitor the annual cost of the air compressor for savings is less than the sum of the
The following working example provides a system, it is also important to ensure that savings for individual measures. The total
useful guide: a 75kW compressor operates at alternatives are compared based on ‘whole possible savings must be calculated as a
7 bar. It is on load for 80% of the production life’ cost, not just the initial capital outlay. By product of efficiency gains. It should be
time, which is 2000 hours per year. Energy opting for equipment that is a higher cost but considered that the efficiency gain of each
consumption of the compressor = 75 x 0.8 x is more efficient, sites could benefit from both measure acts on the residual compressed air
2,000 = 120,000 kWh/year. If electricity lower running costs and total cost of system energy consumption.

WHY OUR RENTAL SERVICE IS THE BEST

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LET’S TALK
Debbie Mayes, Account Manager Rental UK & Ireland
+44 (0) 7 903 645 925 debbie.mayes@aerzenrental.com

AERZEN Rental provides immediate assistance throughout Europe if it concerns 100 % oilfree process air.
With blower and compressor systems for conveyance of air and neutral gases for almost every industry
segment, you are well prepared for any situation. Whether, for example, in case of overproduction, failure
or maintenance, process optimisations or new buildings and conversions. Decide on absolute process
safety: with the 24/7 rental service for efficient assembly solutions including accessories – also turnkey
including installation, commissionning and maintenance. Fast, flexible, reliable.
www.aerzen.com

Service-Rental_DIN A5-V2.indd 1 11.12.2019 09:00:55

 SAVE THE DATE
30 April 2024
MTC, Coventry

DFA Media Group

info@talkingindustry.org
talkingindustry.org +44 (0)1732 370 340

23_pwe_0923.indd 1 08/08/2023 14:31

24-25_pwe_0923.qxp_29_H&P_0308 01/08/2023 10:23 Page 24

25 Years of innovation...

1998 Bowman started manufacturing the BOSS

separator and selling carbon filter
service products

2004 The first SEPURA separator concept was

born - originally a carbon media product

2009 SILEXA was invented (originally marketed

as Sterling Media)

2010 The SEP60ST was launched

2012 The introduction of the High Capacity

SEP3500 & 7000 units

2013 ISO9001 accreditation obtained

Making the grade…
2015 FSC approval obtained
Bowman Stor reinforces a longstanding
2015 SEP1250 & 2500 model along with
commitment to promoting a cleaner
the D range of products
environment with its latest accreditation…
2015 Service indicator launched and supplied as Bowman Stor is proud to have achieved certification for the
standard part of kit ISO 14001 environmental management standard for the
design, manufacture and supply of filters and filtration
2016 Multi-Port adaptor offered to enhance equipment.
exisiting product range flexibility
The accreditation is an important milestone for the company
2017 Wall Mounting Bracket launched for behind the groundbreaking SEPURA™ range of compressed
SEP120 and SEP360 units air condensate filters. Bowman’s tireless development work in
the field of oil/water separation has made a vast contribution
2018 Management Buy Out to the endeavour for a cleaner environment for many years.

SEPURA units utilise a patented, filtration media known as

2020 DIBt approval obtained
SILEXA™. Produced from recycled glass, the unique filtration
product - developed in Bowman’s own laboratories and only
2021 Launch of the free Product Selector App.
found in genuine SEPURA equipment - is able to yield
available on Android and Apple IOS
oil/water output levels of lower than 10ppm.

2022 ISO14001 obtained Managing Director Richard Potts believes that the new
accreditation is a testament to Bowman’s commitment to
2023 25 Years in Manufacturing creating a greener future “Helping industry comply with its
environmental targets has always been at the core of our
2023 New product for the Rail industry operation and we are always striving to evolve our products
to be introduced and find better, more efficient manufacturing solutions. Now,
with the 14001 standard, we can also show that our own
For more information on this and other new organisation meets the most stringent standards across every
products and services, follow us on social aspect of the production process.”
media to keep up to date -
search for Bowman Stor
24-25_pwe_0923.qxp_29_H&P_0308 01/08/2023 10:23 Page 25

25 years of excellence
Creator of the world-leading SEPURA™
range of oil water separators - filtration
specialist Bowman Stor, is celebrating
twenty five years of trading.

Incorporated in 1998, Bowman Stor used

it’s own Research and Development facility
to produce and evolve an extensive,
ground-breaking range of oil and water
condensate separators and replacement
filter kits and has become one of the largest
OEM filter manufacturers in Europe.
The firm introduced the revolutionary
SEPURA concept to the
global filtration market
in 2004 and was
soon to develop its
own unique brand of
filtration media -
SILEXA™ - helping
industry meet
environmental The only place to order...
targets and
promoting a cleaner future. Customers who want the superior condensate filtration
associated with genuine SEPURA separators and filters can
ONLY obtain them through SEPURA’s designated distributors.
Never one to dwell on past achievements, Bowman’s MD
To place an order or for Multi Factor Europe Ltd.,
Richard Potts commented: “We’ve accomplished a vast
further information on t: 01978 855995
amount since our formation but I truly believe that this is SEPURA’s unique range of e: sales@mfeuk.co.uk
only the beginning. We are constantly looking ahead, filtration products contact: or visit our website:
striving for new developments, new improvements, and
always ready for the next challenge.” sepura-technologies.com

scan the code to go to the download page

Make life easier

Get the free App
We have developed a mobile App that will make it
easy to identify the right SEPURA™ product to fit
your current oil/water filtration system.

Not only that, we have also built in a calculator so

you will know straight away which product from our
comprehensive range is the correct one for you.

Our unique SILEXA™ filtration media is made from

recycled materials and is more effective than any other
filtration media currently available. Many users are now
switching to our products over their existing OEM
suppliers to meet their environmental commitments.
SEPURA™ is part of the Bowman Group

t: +44 (0)1543 379212

www.sepura-technologies.com e: sales@sepura-technologies.com
26_pwe_0923.qxp_Layout 1 07/08/2023 12:09 Page 26

Process, Controls & Plant

Whisper vane Expanded VSRT range Optical sensors

transfer pump The new 0330 Optical Sensor from sensing and instrumentation
The XD4 pump from VARNA PRODUCTS delivers up to specialist BAUMER is the latest addition to its ever-expanding
4 gpm (15 l/m) of oil flow. It is a self-priming and quiet- photoelectric range of sensors combining smart design features
running vane pump for use in a wide variety of transfer with high performance reserve capacities. Reliable and
applications with non-corrosive fluids such as oils and economical object detection has become a crucial requirement
coolants. It can produce over 60 psi (4.1 bar) pressure in today’s increasingly automated systems across a wide range
at nominal voltages of 12 thru 24vdc. of industry sectors, so the introduction of these sensors is well
The pump itself produces flow not pressure. Like a timed. Typical applications across a wide range of industry
turnstile, every rotation of the pump delivers a metered sectors include; intra-logistics, electronics manufacturing, textile
volume to the other side. Whatever system is connected machines and packaging applications.
to the pump has flow resistance, which is the source of Whilst standard compact light barriers and photoelectric
the backpressure as the pump works to maintain flow. FULTON has introduced two new larger outputs to proximity sensors are widely available, the ultra-compact 0330
Designed for continuous duty applications with harsh expand its VSRT range and open new markets. At sensor provides enhanced performance reserve capacity with
and poor lubricity fluids. Maximum temperatures to launch, the seven-model VSRT range was available features such as 3D MCAD data and integrated beam path, as
200 C, viscosity to 25,000 cst, weight 4 kgs, self with outputs from 160 to 960 kg/h, but with demand a starting point.
priming to 1.5 metres, wetted parts anodised aluminum. increasing for an energy efficient boiler with larger w| www.baumer.com/gb/en/
Visit www.pwemag.co.uk for the full release outputs like those of horizontal reverse-flame steam www.baumer.com/O330
t| 31 71 5173947 e| esenl@fastmail.com boilers, Fulton is now expanding the range and
www| https://varnaproducts.com/ introducing two new re-designed VSRT models with
outputs of 1565 and 1956 kg/h.
Commenting for Fulton, Managing Director Carl
Knight says: “These new models are ground-breaking
for their output range! When you consider the VSRT-
100 and VSRT-125 models, there are no truly-efficient
tubeless vertical steam boilers in the marketplace with
similar output ranges, the VSRT is the only tubeless
boiler available with the capability of efficiently
producing nearly two tonnes per hour of steam.”
w| www.fulton.co.uk

Indoor Ambient Ultrasonic sensor is a versatile all-rounder

Condition (IAC) sensor SICK has announced it has added the UC40, a
powerful and compact cube sensor, to its market-
CS INSTRUMENTS says its new Indoor Ambient leading family of ultrasonic sensors. The company
Condition (IAC) sensor helps with this measurement task says the SICK UC40 sets the standard for wide-
and with monitoring intake conditions. The intake or ranging ultrasonic detection duties up to 5m.
ambient air influences the compressed air generation Equipped with push-lock mounting and IO-Link, it
and treatment. This should be monitored and evaluated can be quickly integrated in machinery, on
stationarily with suitable measuring technology. conveyors and on automated mobile vehicles.
When designing compressed air stations, the installation The SICK UC40 is a versatile all-rounder for
site and the climatic conditions throughout the year must demanding industrial conditions, outputting reliable
be taken into account. The greatest possible challenges distance or level measurements even in poor
should be expected here. Large temperature fluctuations ambient light, dusty or dirty environments. The
between day and night or winter and summer, lead to UC40 also ensures reliable presence detection
fluctuating delivery quantities and demands on the and position data independent of gloss, colour,
treatment. Since warm air can absorb more water vapor transparency or reflectivity of the detected object. It
than cold air, more water vapor is transported into the is therefore ideal for use in logistics materials
system on warm days than on cold days. In the worst handling and packaging machinery, for example.
case, excessively humid intake air can cause water to w| www.sick.co.uk
accumulate in the compressor during compression. This
can lead to a deterioration in the performance.
w| www.cs-instruments.com
New downflow booth
AIRBENCH has announced the release of its new downflow
booth model, the VertEx DFB. DFB is designed for use in high-
end manufacturing environments, including food and
pharmaceutical manufacturing; but can also be applied in wider
industry settings.
Downflow booths function by providing a flow of clean, filtered
air downwards from the roof of the enclosure, over the operator.
This ensures the operator remains in a clean air zone at all times.
Air is drawn in at the base of the unit, through primary and
secondary filters, before being recirculated back through the
final stage H13 HEPAs to the operator. A percentage of air is
exhausted back to the workspace, ensuring the booth remains in
negative pressure at all times.
t| 01206 791191 e| sales@airbench.com
w| www.airbench.com/products/
vertex-cross-draught-systems/vertex-dfb/

26 | Plant & Works Engineering www.pwemag.co.uk August/September 2023

 MIG
WELDERS
135TE
NEW
492 PAGE
Quality machines
from Britain’s leading CATALOGUE
supplier. See online for
included accessories GET YOUR
GAS, TIPS,
SHROUDS
65SUPERSTORES
NATIONWIDE FREE COPY!
IN-STORE
Model Min-Max Amps exc.VAT inc.VAT & WIRE IN
STOCK
PHONE
PRO90 24-90 £249.00 £298.80
0844 880 1265
135TE Turbo
151TE Turbo
INDUSTRIAL
30-130
30-150
£296.99
£345.00
£356.39
£414.00 HEADER
FROM ONLY
249EXC.VAT
£ .00
Britain's Tools & ONLINE
MIG230TEC
MIG270TE
30/210
30/260
£739.00 £886.80
£899.00 £1078.80
£298.80 inc.VAT
Machinery Specialist! www.machinemart.co.uk

MMA & ARC/TIG TURBO FAN GAS 145 Bar

INVERTER WELDERS Offering low cost, HEATERS 2100 psi
HOT
FROM ONLY FROM ONLY
efficient heating
104
£ DOUBLE
DOUBLE
.99
exc.VAT
£125.99 FOOTER
inc.VAT
WASHERS INDUSTRIAL £2399DOUBLE .00
DUAL EXC.VAT
VOLTAGE
230& SCREW DOUBLE FOOTER
£2878.80 inc.VAT

110 FROM ONLY 579

£ FROM ONLY
.00
DOUBLEEXC.VAT COMPRESSORS
VOLT 94
£ DOUBLE.99
DOUBLEEXC.VAT PROPANE DOUBLE
£694.80 FOOTER
inc.VAT
IN STOCK
FROM £224.40
FOOTER
£113.99 inc.VAT GAS FIRED 40HP +
Model
Max. Output
kW exc.VAT inc.VAT 148.3cfm
Min/Max Electrode Little Devil II 10.3 £94.99 £113.99
Output Dia. Devil 700 15 £119.98 £143.98 INC. CONTAINER CXR40
Model Current (mm) exc.VAT inc.VAT Devil 900
MMA140A 20A-140A 1.6-3.2 £104.99 £125.99 Devil 1600
24.9
36.6
£159.98
£189.98
£191.98
£227.98
FOR DETERGENT AMAZING LOW PRICE! 5.5HP +
10 bar Proven reliability Super silent
MMA200A 20A-200A 1.6-3.2 £139.98 £167.98 Devil 2100
AT165 10A-160A 2.5/3.2/4.0 £219.98 £263.98 Devil 4000
49.8
131
£269.00
£479.00
£322.80 Model BAR Press. VOLT exc.VAT inc.VAT
£574.80 Harry 2 145 2100psi 230 £579.00 £694.80
17.1cfm Easy maintenance Full digital control
KING 200 150 2175psi 230 £1198.00 £1437.60 Superb build quality. Meets European standards
ELECTRIC *Includes Air Receiver and Dryer
DIESEL/PARAFFIN HEATERS INDUSTRIAL Model cfm Hp RCVR exc.VAT inc.VAT
HEATERS STEEL BOLTLESS SHELVING CX3MR 8.5 3 200ltr £2399.00 £2878.80
DEVIL CXR5R 17.1 5.5 200ltr £2565.00 £3078.00
Ideal for fast efficient heating
Extra-long run fuel tanks – up to BEST 6003 Quick and easy assembly, only a hammer is CXR100 37.1 10 – £2995.00 £3594.00
53 litres SELLER required Strong 8mm fibreboard shelves CXR100R 37.1 10 270ltr £3295.00 £3954.00
PRICE CUT Adjustable shelf height
Variable heat MANY SIZES CXR15 53 15 – £3535.00 £4242.00
output with
DEVIL
7003
64exc.VAT
£ DOUBLE
.99
£77.99 inc.VAT
2000(W) x 600(D) x 2000mm(H) CXR15R 53 15 270ltr £3895.00 £4674.00
thermostat WAS £83.98 inc.VAT
CXR5R CXR20 65.3 20 – £3795.00 £4554.00
control FROM ONLY CXR20R 65.3 20 500ltr £4395.00 £5274.00
229
£DOUBLE.00
DOUBLE
EXC.VAT
£274.80 FOOTER
HEAT
MODEL VOLTAGE OUTPUT
exc. WAS
VAT inc.VAT
inc.
VAT
EXTRA HIGH Full range includes floor & receiver mounted CXR30 106
CXR40 148.3 40
30 –
–
£6395.00 £7674.00
£7895.00 £9474.00
inc.VAT 78" 2000mm with/without built-in dryer Air receivers,
Devil 6003 230V 1.5-3kW £64.99 £83.98 £77.99 CXR50 187 50 – £9395.00 £11274.00
* WAS £502.80 inc.VAT XR80 Devil 7003 230V 3kW £69.98 £92.39 £83.98 dryers & filters also available separately
from only £129.00 exc.VAT CXR60 229 60 – £10995.00 £13194.00
¥ WAS £574.80 inc.VAT Devil 7005 400V 5kW £97.99 £118.79 £117.59 CXR75 275 75 – £12195.00 £14634.00
PRICE CUT £154.80 inc.VAT
model MAX output exc.VAT inc.VAT Devil 6009 400V 4.5-9kW £119.98 £149.99 £143.98 HUGE 600kg
XR60 14.7kW £229.00 £274.80 Devil 7009 400V 9kW £149.98 £183.59 £179.98
£
259
DOUBLE.00
exc.VAT CAPACITY PER SHELF
CXR110 371 100 – £15595.00 £18714.00
XR80 20.5kW £279.00 £334.80 Devil 6015 400V 5-10-15kW £179.98 £227.98 £215.98 £310.80 inc.VAT
WAS £322.80 inc.VAT
PETROL & DIESEL INDUSTRIAL AIR
XR110 29.3kW £329.00 £394.80 Devil 7015 400V 15kW £219.98 £275.98 £263.98 PRESSURE COMPRESSORS
XR160* 46.9kW £399.00 £478.80 Honda & Diesel WASHERS
XR210 ¥ 61.5kW £459.00 £550.80 HYDRAULIC EXTRA WIDE
78" 2000mm engine models Top quality belt driven air compressors for industrial &
LIFTING TABLES in stock PLS265B CAN commercial users inc; garages, factories, workshops
1 TONNE • Ideal for lifting HEADER
FROM ONLY DRAW and farms. 10 bar/150psi max working pressure
OWN
FOLDING & moving models £
279EXC.VAT
.00
WATER
WORKSHOP • Foot pedal operated £334.80 inc.VAT
PRICE CUT * WAS £478.80 inc.VAT
CRANE NOW FROM ONLY
HTL500 CSA30FP
# WAS £502.80 inc.VAT
Folding and fixed
frames available
£
439exc.VAT.00
£526.80 inc.VAT
HYDRAULIC NOWPRICE CUT
FROM ONLY
‡ WAS £634.80 inc.VAT
Robust, rugged WAS £538.80 inc.VAT PRESSES £169.98 ◆ WAS £838.80 inc.VAT
exc.VAT ▼ WAS £958.80 inc.VAT
CFC100 construction *Diesel
PRICE CUT Max. Table Height exc. WAS inc. PROFESSIONAL WAS £203.98 inc.VAT
£209.99 inc.VAT Pressure Engine
Overload safety valve Model Load Mon-Max VAT inc.VAT VAT QUALITY
£
219
DOUBLE.98
exc.VAT HTL300 300kg 340-900mm £439.00 £538.80 £526.80 Built for tough daily use in Model BAR/Psi HP
Tiger1800B 110/1595 3
exc.VAT inc.VAT
£279.00 £334.80
£263.98 inc.VAT Fully tested HTL500 500kg 340-900mm £479.00 £586.80 £574.80 automotive/industrial workshops
WAS £287.98 inc.VAT
to proof load * Available with/without 7 Tiger2600B* 180/2610 4 £379.00 £454.80
pce pin, bracket & pressing Tiger3000B# 200/2900 6.5 £399.00 £478.80
plate kit # Economy model PLS195B‡ 180/2640 5.5 £499.00 £598.80 †V-Twin
PLS220◆ 230/3335 9 £679.00 £814.80 XEV16/100 *230V
PORTABLE 1 TONNE GANTRY ^ WAS £209.99 inc.VAT PLS265B ▼ 225/3263 13 £769.00 £922.80
PRO TOOL ≈ WAS £1197.60 inc.VAT † WAS £2230.80 inc.VAT
CHESTS CRANE Model exc.VAT inc.VAT
PLS360 248/3600 13 £998.00 £1197.60 AIR.
DLS200AL* 200/2900 8.5 £2395.00 £2874.00 DISP MOTOR AIR
& CABINETS Tough steel CSA4B-4 tonne bench#^ £169.98 £203.98
2kW MODEL CFM (HP) RCVR EXC.VAT INC.VAT
construction CSA10EP 10 tonne bench* £194.99 £233.99 GARAGES/WORKSHOPS
1000 XEV16/100 (OL)†* 14 3 100ltr £589.00 £706.80
PRICE CUT
1 ’I’ beam cross CSA12F 12 tonne floor*# £379.00 £454.80
£
159exc.VAT
DOUBLE.98
£191.98 inc.VAT
member for
KG
CSA20FBT 20 tonne floor £499.00 £598.80
PRICE CUT
NOW FROM ONLY
IDEAL FOR RAIN &
SUN PROTECTION
XEV16/150 (OL)†*
XEV16/200(OL)†*
14
14
3 150ltr
3 200ltr
£659.00 £790.80
£719.00 £862.80
WAS £203.98 inc.VAT added strength CSA30FPB 30 tonne floor ≈ £959.00 £1150.80
CSA50FPB 50 tonne floor † £1799.00 £2158.80
£
259exc.VAT
.00
£310.80 inc.VAT
XEV16/150(400V)† 14 3 150ltr £699.00 £838.80
ADJUSTABLE WAS £346.80 inc.VAT
XE37/270 (OL)* 36 2x 4 270ltr £1479.00 £1774.80
HEIGHT SUBMERSIBLE CDP102B
PRICE CUT 2 2520-3600MM
WATER PUMPS
NOW FROM ONLY CAT117
PRICE CUT LENGTH DRILL PRESSES
£
289exc.VAT
.00
£346.80 inc.VAT 569exc.VAT
£ DOUBLE.00 FROM ONLY
49
£ DOUBLE
.98
DOUBLE
UP TO
Range of precision bench
CHROME £682.80 inc.VAT EXC.VAT 40'
WAS £382.80 inc.VAT
SPOKED WAS £718.80 inc.VAT CWGC1000 FOOTER
£59.98 inc.VAT & floor presses for enthusiast,
WHEELS engineering & FROM ONLY
* WAS £113.99 inc.VAT
Model Description exc.VAT inc.VAT 3-IN-1 BRIGHT WHITE
industrial
applications
99
£ DOUBLE
DOUBLE
.95
EXC.VAT
FOOTER
£119.94 inc.VAT
CBB203C* 3 Dr step up £89.98 £107.98 SBR610 SHEET INTERIOR
B = Bench
1 CBB209C 9 Dr Chest £159.98 £191.98
2 CBB217C 7 Dr Cabinet £289.00 £346.80 METAL Ideal for use as a garage
* WAS £418.80 inc.VAT mounted
workshop Extra tough triple
MACHINES The Famous layer cover Heavy duty powder CIG1640 # WAS £418.80 inc.VAT F = Floor standing
• Bend, Roll & Shear Hippo pump ‡ WAS £946.80 inc.VAT
5 TONNE coated steel tubing Ratchet tight tensioning
#Auto ON/OFF float switch on these size (LxWxH) WAS NOW
FORKLIFT JACK LOW models ‡Sewage cutter pump Model m exc.VAT inc.VAT inc.VAT Motor (W)
LIFTS FROM ONLY
249
£ FROM ONLY
.00
DOUBLEEXC.VAT
DOUBLE
£298.80 FOOTER
inc.VAT
FROM
70mm £
319
DOUBLE.00
EXC.VAT Model
Max Max
Flow Head exc.VAT inc.VAT
CIG81212 3.6 x 3.6 x 2.5 £259.00 £346.80 £310.80
CIG81015 4.5 x 3 x 2.4 £279.00 £370.80 £334.80
model
CDP5EB
Speeds
350/5
exc.VAT
£99.95
inc.VAT
£119.94
HIGH ROLLING, SHEARING & FOLDING DOUBLE
£382.80 FOOTER
inc.VAT PSV3A# 133L 8M £49.98 £59.98 CIG81216 4.9 x 3.7 x 2.5 £329.00 £430.80 £394.80 CDP102B
CDP152B
350/5
450/12
£115.95
£209.98
£139.14
£251.98
LIFTS * WAS £742.80 inc.VAT # WAS £886.80 inc.VAT PSV1A# 140L 5.8M £59.98 £71.98 CIG81020 6.1 x 3 x 2.4 £349.00 £466.80 £418.80
UPTO
Model Bed Width exc.VAT inc.VAT HIPPO 2 230V 85L 6M £69.98 £83.98 CIG81220 6.1 x 3.7 x 2.5 £399.00 £514.80 £478.80 CDP202B 450/16 £269.00 £322.80
730mm CDP352F* 550/16 £339.00 £406.80
SBR305 305mm (12") £319.00 £382.80 PSV4A# 216L 8M £59.98 £71.98 CIG81224 7.3 x 3.7 x 2.5 £499.00 £646.80 £598.80
AND CFT5B SBR610* 610mm (24") £598.00 £717.60 PVP11A‡# 258L 11.0M £89.98 £107.98 CIG1432 9.7x4.3x3.65 £1099.00 – £1318.80 CDP452B# 550/16 £339.00 £406.80
COMMERCIAL
VEHICLES
SBR760# 760mm (30") £699.00 £838.80 HSEC650A‡# 290L 9.5M £249.00 £298.80 CIG1640 12x4.9x4.3 £2899.00 £3838.80 £3478.80 CDP502F‡ 1100/12 £779.00 £934.80
V
VISIT YOUR LOCAL SUPERSTORE OPEN MON-FRI 8.30-6.00,
SAT 8.30-5.30, SUN 10.00-4.00
5 EASY WAYS TO BUY...
BARNSLEY Pontefract Rd, Barnsley, S71 1EZ 01226 732297 EXETER 16 Trusham Rd. EX2 8QG 01392 256 744 NORWICH 282a Heigham St. NR2 4LZ 01603 766402 SUPERSTORES
B’HAM GREAT BARR 4 Birmingham Rd.
B’HAM HAY MILLS 1152 Coventry Rd, Hay Mills
0121 358 7977
0121 7713433
GATESHEAD 50 Lobley Hill Rd. NE8 4YJ
GLASGOW 280 Gt Western Rd. G4 9EJ
0191 493 2520
0141 332 9231
NORTHAMPTON Beckett Retail Park, St James’ Mill Rd 01604 267840 NATIONWIDE
NOTTINGHAM 211 Lower Parliament St. 0115 956 1811
BOLTON 1 Thynne St. BL3 6BD 01204 365799 GLOUCESTER 221A Barton St. GL1 4HY 01452 417 948 PETERBOROUGH 417 Lincoln Rd. Millfield 01733 311770
BRADFORD 105-107 Manningham Lane. BD1 3BN 01274 390962 GRIMSBY ELLIS WAY, DN32 9BD 01472 354435 PLYMOUTH 58-64 Embankment Rd. PL4 9HY 01752 254050 ONLINE
BRIGHTON 123 Lewes Rd, BN2 3QB
BRISTOL 1-3 Church Rd, Lawrence Hill. BS5 9JJ
01273 915999
0117 935 1060
HULL 8-10 Holderness Rd. HU9 1EG
ILFORD 746-748 Eastern Ave. IG2 7HU
01482 223161
0208 518 4286
POOLE 137-139 Bournemouth Rd. Parkstone
PORTSMOUTH 277-283 Copnor Rd. Copnor
01202 717913
023 9265 4777
www.machinemart.co.uk
BURTON UPON TRENT 12a Lichfield St. DE14 3QZ 01283 564 708 IPSWICH Unit 1 Ipswich Trade Centre, Commercial Road 01473 221253 PRESTON 53 Blackpool Rd. PR2 6BU 01772 703263
CAMBRIDGE 181-183 Histon Road, Cambridge. CB4 3HL 01223 322675
CARDIFF 44-46 City Rd. CF24 3DN 029 2046 5424
LEEDS 227-229 Kirkstall Rd. LS4 2AS
LEICESTER 69 Melton Rd. LE4 6PN
0113 231 0400
0116 261 0688
SHEFFIELD 453 London Rd. Heeley. S2 4HJ 0114 258 0831 TELESALES
CARLISLE 85 London Rd. CA1 2LG 01228 591666 LINCOLN Unit 5. The Pelham Centre. LN5 8HG 01522 543 036
SIDCUP 13 Blackfen Parade, Blackfen Rd
SOUTHAMPTON 516-518 Portswood Rd.
0208 3042069
023 8055 7788
0115 956 5555
CHELTENHAM 84 Fairview Road. GL52 2EH 01242 514 402 LIVERPOOL 80-88 London Rd. L3 5NF 0151 709 4484 SOUTHEND 1139-1141 London Rd. Leigh on Sea 01702 483 742
CHESTER 43-45 St. James Street. CH1 3EY 01244 311258 LONDON CATFORD 289/291 Southend Lane SE6 3RS 0208 695 5684
COLCHESTER 4 North Station Rd. CO1 1RE 01206 762831 LONDON 6 Kendal Parade, Edmonton N18 020 8803 0861
STOKE-ON-TRENT 382-396 Waterloo Rd. Hanley
SUNDERLAND 13-15 Ryhope Rd. Grangetown
01782 287321
0191 510 8773
CLICK & COLLECT
COVENTRY Bishop St. CV1 1HT 024 7622 4227 LONDON 503-507 Lea Bridge Rd. Leyton, E10 020 8558 8284 OVER 10,500 LOCATIONS
SWANSEA 7 Samlet Rd. Llansamlet. SA7 9AG 01792 792969
CROYDON 423-427 Brighton Rd, Sth Croydon 020 8763 0640 LUTON Unit 1, 326 Dunstable Rd, Luton LU4 8JS 01582 728 063
SWINDON 21 Victoria Rd. SN1 3AW 01793 491717
DARLINGTON 214 Northgate. DL1 1RB 01325 380 841 MAIDSTONE 57 Upper Stone St. ME15 6HE 01622 769 572
TWICKENHAM 83-85 Heath Rd.TW1 4AW 020 8892 9117
CALL & COLLECT
DEAL (KENT) 182-186 High St. CT14 6BQ 01304 373 434 MANCHESTER ALTRINCHAM 71 Manchester Rd. Altrincham 0161 9412 666
DERBY Derwent St. DE1 2ED 01332 290 931 MANCHESTER CENTRAL 209 Bury New Road M8 8DU 0161 241 1851 WARRINGTON Unit 3, Hawley’s Trade Pk. 01925 630 937

SAME DAY
DONCASTER Wheatley Hall Road 01302 245 999 MANCHESTER OPENSHAW Unit 5, Tower Mill, Ashton Old Rd 0161 223 8376 WIGAN 2 Harrison Street, WN5 9AU 01942 323 785
DUNDEE 24-26 Trades Lane. DD1 3ET 01382 225 140 MANSFIELD 169 Chesterfield Rd. South 01623 622160 WOLVERHAMPTON Parkfield Rd. Bilston 01902 494186
EDINBURGH 163-171 Piersfield Terrace 0131 659 5919 MIDDLESBROUGH Mandale Triangle, Thornaby 01642 677881 WORCESTER 48a Upper Tything. WR1 1JZ 01905 723451
Calls to the catalogue request number above (0844 880 1265) cost 7p per minute plus your telephone company’s network access charge. For security reasons, calls may be monitored. All prices correct
33479
*
at time of going to press. We reserve the right to change products and prices at any time. Check online for latest prices. All offers subject to availability, E&OE. Terms & conditions apply see machinemart.co.uk/finance for more details

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Process, Controls & Plant Focus on: Seals, Bearings & Lubrication

Making industrial
furnaces more
energy-efficient
With industrial furnaces being one of the biggest energy consumers, it’s no surprise that
manufacturers are investing in research and development to create more energy-efficient
solutions. Chris Johnson* explains why high-temperature bearings will be crucial in making
industrial furnaces more energy-efficient.

E
ven as countries strive to meet climate stainless steel bearings can withstand and wear, resulting in reduced energy
goals and reduce their carbon temperatures of up to 300 °C with the right consumption and enhanced operational
footprint, the current rate of lubrication. Beyond these thresholds, alternative efficiency. The selection of the appropriate
improvement is not sufficient to meet the materials must be employed. bearing material ensures optimal performance
targets set out by the Paris Agreement. At higher temperatures, full ceramic bearings and reliability in diverse temperature
According to the International Energy without ball retainers, also known as full environments.
Agency (IEA), in 2022 the global economy complement bearings, are utilised. These
used energy two per cent more efficiently than bearings find application in temperatures above Driving factors
it did in 2021. While this is an improvement, 300 °C, as well as in situations where The demand for energy-efficient furnaces is
there is still some way to go and energy lubrication poses a challenge, such as due to growing rapidly, driven by a range of factors.
efficiency improvements need to average 4 per contamination. Full complement ZrO2 ceramic One of the most significant drivers is political,
cent a year this decade to align with the bearings can be employed in temperatures up with governments around the world setting
IEA’s Net Zero Emission by 2050 Scenario. to 600 °C, while full complement Si3N4 ambitious climate goals to reduce carbon
This increasing emphasis on reducing carbon bearings have demonstrated successful emissions and combat climate change. This has
emissions and energy consumption, there is a performance up to 1200 °C. led to increased regulations and incentives for
growing demand for energy-efficient industrial By employing high-temperature bearings, businesses to reduce their carbon footprint and
furnaces. As a result, manufacturers are manufacturers can effectively minimise friction improve energy efficiency.
investing in R&D to develop advanced furnaces
that consume less energy, emit fewer pollutants
and ensure better combustion efficiency.

High-temperature bearings
Industrial furnaces operate at extremely high
temperatures and often in harsh environments,
which can cause significant wear and tear on
the machinery. Bearings are a critical
component of these machines, as they help to
reduce friction and wear between moving
parts. However, at high temperatures, traditional
bearings can fail, causing damage to the
furnace and reducing its efficiency.
High-temperature bearings are designed to
withstand extreme temperatures and harsh
environments, making them the ideal solution for
industrial furnaces.
Bearings are essential components in various
mechanical systems, designed to reduce friction
and wear. The materials used for manufacturing
bearings depend on the temperature
requirements of the application. For
temperatures up to 150 °C, chrome steel
bearings are suitable when paired with an Bearings are critical components in industrial furnaces,
as they help to reduce friction and wear between moving parts.
appropriate lubricant. Meanwhile, 440 grade

28 | Plant & Works Engineering www.pwemag.co.uk August/September 2023

19_p
28-29_pwe_0923.qxp_Layout 1 09/08/2023 10:26 Page 29

Focus on: Seals, Bearings & Lubrication Process, Controls & Plant

Another factor driving demand is the growing risk of costly lawsuits and damage to the In doing so, they can help drive the transition
industrial sector, particularly in countries such as company’s reputation. towards more energy-efficient industrial
China and India. As these countries continue to As countries strive to meet the climate goals furnaces and contribute towards a greener
develop, the demand for energy-efficient set out by the Paris Agreement, industrial future.
furnaces will increase, as manufacturers seek to furnaces, being significant energy consumers,
reduce costs and improve their efficiency must become more energy efficient. For further information please visit
further. Specialised high-temperature bearings are http://www.smbbearings.com/
Finally, technological advancements are also essential in this endeavour. These specialised
driving demand, with new materials and bearings withstand extreme temperatures and *Chris Johnson is managing director at
designs being developed to improve energy harsh environments, reducing friction and wear. specialist bearing supplier SMB Bearings
efficiency and reduce emissions. High-
temperature bearings are just one example of Full ceramic bearings without ball retainers,
also known as full complement bearings,
this, with manufacturers investing in R&D to are used in temperatures above 300
create new and innovative solutions.

Benefits of investing
Investing in high-temperature bearings offers
a range of benefits for businesses. In addition
to the obvious environmental benefits, they
can also help to extend the life of the
furnace, reducing maintenance costs and
downtime.
In addition, high-temperature bearings can
improve overall safety and reliability, reducing
the risk of equipment failure and accidents. This
can have a significant impact on productivity
and employee morale, as well as reducing the

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Energy & Environmental Management Focus on: Boilers, Burners & Controls

Thermal Oxidisers:
Efficient odour abatement
Etienne Fourie, Technical Sales Manager at Babcock Wanson, explains the use of
Thermal Oxidisers in the food industry.

G
as and VOC (Volatile Organic remove the frying process odour from the effluent in the combustion chamber between 0.6
Compounds) effluent produced by exhaust gas. The pollutant gases are heated to and 1 second and there must be adequate
food manufacture – primarily meat 850°C in the combustion chamber and are fully turbulence for efficient mixing of effluent and
processing, frying and roasting - oxidised before being discharged to the oxygen.
have to be treated before being discharged to atmosphere as a harmless gas. Each Oxidiser Regenerative Oxidisers are just as effective as
the atmosphere in order to meet prevailing burns up to 4000 kg/h of fryer exhaust and in Recuperative Oxidisers and have some added
regulations, including The Solvent Emissions doing so recovers valuable heat which is fed benefits, including lower NOx emissions,
Directive and The Environmental Permitting back to a thermal fluid to heat the production reduced gas/fuel consumption, reduced
(England and Wales) Regulations. The most line, thereby recycling the energy back to the maintenance requirements and, as it is a self-
effective and widely used for VOC and odour process. The recovered heat is also used to contained plant, it does not produce waste heat.
treatment is Thermal Oxidation. Pollutant gases produce steam for processing needs and to Moy Park’s Grantham, Lincolnshire, facility
are heated to a high temperature in a heat washdown water therefore helping to meet benefits from a Regenerative Thermal Oxidiser
combustion chamber and are fully oxidised the sites total demand in an efficient manner. to provide an effective odour abatement
before being discharged as a harmless gas. solution for the sites’ frying and oven based
Thermal Oxidisers are designed and Regenerative Oxidisers cooking processes.
manufactured to recover heat energy externally Regenerative Oxidisers are used where there is One of Europe’s leading food companies,
(Recuperative Oxidisers) or internally no requirement for heat recovery or the amount Moy Park specialises in fresh poultry and
(Regenerative Oxidisers). Which of these types of heat that can be recovered is too small to complementary convenience food products. Its
is more appropriate is usually dependent upon justify a Thermal Recovery Oxidiser. Grantham premises is a large further processing
the composition and delivery volume of the The VOC laden air from the process is drawn site for breaded and ready to eat produce
polluted air and the concentration of VOCs. into the Oxidiser by means of a motor driven featuring six production lines. Both frying and
Modern Oxidisers incorporating adsorption centrifugal fan. The effluent is heated in the oven cooking methods are used at the site,
technology concentration techniques can bring incoming tower, passed through the combustion which has grown rapidly over recent years.
even the largest air volumes with low solvent chamber and cooled by the exit tower, each of With this growth has come the need for
loadings within reach of economic operation. which is filled with specialist ceramic material. improved odour abatement, especially
The Regenerative Oxidiser can achieve auto- important because of the site’s location close to
Recuperative Oxidisers thermal conditions with very low concentrations the town centre.
Pollutant gases are heated to a high of VOC. However, to achieve optimum thermal After a detailed review with the site
temperature – typically 700°C - in a combustion oxidation of the VOC, the temperature must be engineering team, Babcock Wanson
chamber for 0.6 – 2.0 seconds to fully oxidise between 750 and 950°C, the dwell time of the recommended replacing the existing Catalytic
them before being discharged into the
atmosphere as a harmless gas. Using Heat
Recovery units, energy is recovered from the
exhaust stream for reuse in the process or
elsewhere, thereby reducing total operating
costs.
Recuperative Oxidisers are targeted at
industrial process where there is a combination
of energy demand and effluent oxidation. These
types of Thermal Oxidisers are mainly suitable
for high VOC concentrations and lower flow
rates.
The key advantages of Recuperative
Oxidisers include a quick start up and high
energy recovery, plus they are safe and reliable,
with full hazard audit.
One Babcock Wanson customer, whose
processing facilities are located in a densely
populated urban area, has used two COMBI
4000 Recuperative Thermal Oxidisers to

30 | Plant & Works Engineering www.pwemag.co.uk August/September 2023

 Boiler Hire
Short or Long Term
You can’t beat

Long Term Short Term

Long term hire can be a cost effective When you need help in a hurry you can depend
alternative to outright purchase. on Byworth for a rapid response. Temporary
• Capital outlay for new plant alleviated boilers provided for:
• Maintenance and servicing costs included • Breakdown cover
• Plant designed and manufactured to suit • Cover for repairs and maintenance
exact needs • Urgent need for extra production capacity
Unity - Byworth’s unique remote monitoring • Short term projects and trials
system available

Trust in the UK’s leading industrial boiler hire company using

the latest fuel efficient boilers, manufactured in our own
factory. Byworth Hire gives total flexibility to cover any
eventuality with full back-up support.

NHS
APPROVED
SUPPLIER

THE QUEEN’S AWARDS

FOR ENTERPRISE: 2006
BYWORTH BOILERS LTD Tel: 01535 662599 | hire@byworth.co.uk | www.byworth.co.uk

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Energy & Environmental Management Focus on: Boilers, Burners & Controls

Thermal Oxidisers with a more effective processing, rendering and coffee and barley
Regenerative Thermal Oxidiser capable of roasting.
treating the complete cooking exhaust stream Unlike standard Thermal Oxidisers, these are
irrespective of the process heat load - an specifically designed plants tailored to meet the
important feature in the fast moving food particular requirements of each site process.
industry. The exhaust air from the cooking Odours are processed at a temperature of up
processes is fed through a heated matrix of to 950°C for approximately 0.8 seconds. A
specialist ceramic honeycombs. It enters the heat recovery boiler recovers energy from the
Oxidiser at around 60°C and is heated to flue gas stream and feeds it back to the process
850°C by the ceramics, with a small burner using steam or thermal fluid. Dwell times are
adding the final heat to get the stream to full adjusted to suit the specific process.
oxidation temperature. The exhaust stream is Deodorising Oxidisers have an overall
treated by passing it through three towers which efficiency over 95%.
operate on a fixed rotation thereby ensuring a
constant treatment profile. The clean, odour free Conclusion
air is then released to the atmosphere. settings. A secondary heat recovery system, No food producer willingly pollutes its
An almost unique project in the food industry, which will provide up to 200kW of hot water surrounding atmosphere with unacceptable
the installation has proven to be very reliable from the clean exhaust air, has also been odours and all are aware that an abatement
with the bare minimum of maintenance or incorporated, thereby increasing the overall notice has a potentially devastating impact on
cleaning requirements to meet its round the efficiency of the system and reducing overall site their business. Assessing odour and ensuring it
clock duties. gas demand. is treated appropriately is a priority, especially
Up to 25,000 Nm3/h of cooking exhaust is for premises in built up areas. Thermal Oxidisers
treated at the site with the minimum of natural Deodorising Oxidisers provide an effective and cost-efficient method of
gas input. It is completely automatic which Deodorising Oxidisers are designed solely to achieving this.
means production lines can be switched on or abate odours and vapour emissions generated
off to meet production requirements without by various production processes and are For further information please visit:
having to make adjustments to the Oxidiser particularly ideal for frying processes, meat www.babcock-wanson.co.uk

Gas Process Burners

Lanemark gas burner systems offer users reliable, high efficiency,
process heating solutions.
FD Series Packaged Oven/Dryer Burners
• Specifically designed for process air heating applications in convection
ovens and dryers
• High turndown/short flame lengths providing accurate process
temperature control
• High efficiency gas + air modulation, gas only modulation and simple
high/low control options
• Heat Input Range: 9 kW – 1550 kW
TX Series Gas Fired Process Tank Heating Systems
• High efficiency (80%+) heating of all types of spray and dip process tanks
FD-C high turndown oven/ FD-E low cost high turndown • Compact high efficiency small diameter immersion tube heat exchangers
dryer air heating burners. oven/dryer air heating burners. occupying minimum tank space
• Accurate performance modelling using Lanemark TxCalc design software
• Heat Input Range: 15 kW (1½") – 1150 kW (8")
Midco HMA Series Air Replacement or “Make-Up” Air Heating Burners
FD-GA modulating gas + air
process air heating burners. • Direct fired, high efficiency burner systems, for high volume air heating
applications such as paint spray booths, ovens and dryers.
• Supplied either as Midco burner heads for OEM system integration or
as Lanemark DB or FDB complete packaged systems including modulating
gas valve trains and controls
• Wide range of firing rates to suit alternative temperature rise and air
velocity system requirements
Midco HMA high efficiency, TX high efficiency small diameter
high turndown, air replacement immersion tube tank heating • DbCalc system design software
or “make-up” air heating burners. systems.

Lanemark Combustion Engineering Limited

Lanemark House, Whitacre Road, Nuneaton, Warwickshire CV11 6BW United Kingdom
Tel: +44 (0) 24 7635 2000 Fax: +44 (0) 24 7634 1166 E-mail: info@lanemark.com
www.lanemark.com COMBUSTION ENGINEERING

32 | Plant & Works Engineering>> www.pwemag.co.uk August/September 2023

 “It is not the strongest of
the species that survives,
nor the most intelligent
that survives.
It is the one that is most
adaptable to change.”
Charles Darwin

In our uncertain environment, energy

adaptability is key. When it comes to
process heating, Babcock Wanson offers
more choice and flexibility to achieve your
decarbonisation goals, reduce your fuel
bill and allow for energy diversification.

Babcock Wanson UK Ltd.

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

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Energy & Environmental Management Focus on: HVAC

CASE STUDY

Heat pump technologies:

Future proofing your
heating system
A plastic packaging manufacturer has future proofed its heating system by replacing
fossil-fuelled equipment with heat pump technologies. PWE reports.

M
any industrial processes like place and operating under different conditions. generating the heat by the new heat pump
food and beverage, plastics, One based on a chiller room and dedicated to systems.
and rubber, chemical and processes requiring 13/18°C temperatures to In the first set-up for the larger space,
pharmaceutical, just to name a work the plastics; the second one dedicated generating the required 366kW of heating with
few, have started looking at heat pumps as an mostly to processes dealing with oil and based the i-FH unit cost over 25% than the fossil-fuelled
efficient heating solution for a wide range of on dry coolers with 25/30°C temperatures. system. Additionally, the customer was able to
processes. As they have been getting Two completely different systems, but perfectly benefit from 223kW of cooling generated by
familiarised with the new technologies, they fitted to work with the industrial Free Heating (i- the i-FH unit in the same time. This additional
have started recognising the economic benefits FH) system from ICS Cool Energy. cooling capacity proved to be crucial when it
from a most efficient use of energy while also as used to offset the cooling load suddenly lost
providing a significant benefit towards emission Heat pump Installation when one of the other chillers suddenly broke
reduction. The existing fossil-fuelled system was delivering down.
A manufacturer of plastic packaging and approximately 600kW of heating. To replace In the set up with the dry-cooler, generation
containers decided to future proof its the old equipment and fulfil that load, the ICS of 254kW of heating with the i-FH unit cost the
operations addressing the rising costs of fossil- Cool Energy team decided to divide the manufacturer over 43% less compared with the
fuel energy and concerns about its availability heating system into two areas corresponding fossil-fuelled system.
and environmental footprint. To do so, it with the existing cooling system. They installed As a result, ICS Cool Energy says the
reached out to the ICS Cool Energy team with two industrial Free Heating (i-FH) heat pumps – customer has not only future-proved its heating
a request to re-design the existing heating one in combination with the chiller room to system but has been saving money and
system based on high-efficiency heat pump deliver 366kW of heating for the space of benefited from the additional cooling capacity
technology. 9000m3, and another one to deliver 254kW that helped in its emergency.
During the site visit, the ICS Cool Energy of heating for 4600m3 in combination with the
team inspected the four office, production and dry-cooler. For further information please visit:
storage buildings requiring heating. They also Following the installation, the customer www.icscoolenergy.com or
examined the two cooling systems already in immediately noted the difference in the cost of www.tranetechnologies.com

34 | Plant & Works Engineering www.pwemag.co.uk August/September 2023

 N
op om
eN iNa
1s tio
t a Ns
ug
us
t

PUMP INDUSTRY
AWARDS 2024

Here’s your chance to shine!

The BPMA’s annual Pump Industry Awards programme has been
recognising and rewarding the achievements of pump businesses,
large and small for over two decades. Throughout that time it Venue: Hilton at St George’s Park,
has become one of the leading events to serve the industrial and Burton upon Trent
commercial arena. So, if you or your company have a pump related Date: Thursday 14th March 2024
success to shout about, these awards provide the perfect platform.

The gala presentation dinner caps off the awards programme in style,
providing excellent networking opportunities, great food and superb
entertainment. It’s your chance to celebrate with colleagues, interact The 2024 entry forms open on the
with peers, entertain customers and be part of the pump industry’s 1st August, so be sure to visit the Pump
biggest and best celebration. Manufacturing and distribution prowess,
product development and application, environmental consideration, skills Industry Awards website to review the
development and customer support will all be acknowledged through this award categories and decide which
wide reaching awards programme. So why not consider which of your ones you will be entering!
engineering successes are deserving of industry wide recognition, and be
sure to join us at our wonderful venue - the home of English football - on
Thursday 14th March 2024.

Dale Croker, BPMA President, says of the Pump

Event Calendar Industry Awards, “The pump industry continues to
be a hotbed of competitiveness, where the constant
Nominations Open: 1 st August 2023 search for greater operational performance and
improved efficiencies amongst its broad customer
Nominations Close: 5 th January 2024 base, demands all those operating within this
Judging Session: Mid-January 2024 important sector to be at the top of their game.
This BPMA backed awards programme allows the
Voting: 12 th-16th February 2024 pump industry to come together in celebration of
that drive for engineering excellence.”
Winners Announced: 14th March 2024

www.pumpindustryawards.com
Award Programme Partners

Organised by on behalf of

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Handling & Safety Matters Focus on: Heath & Safety

Want a safer
workplace?
Then show
the value

Having recently achieved the ISO 45001 certification for Air Products, Rachel Rawlings*,
talks about why plant operators and engineers are central to the success of occupational
health and safety initiatives.

I
n a bustling industrial landscape where for commercial success. A company’s clean bill management team put its weight behind the
plants operate around the clock, a deep of health on safety attracts and retains skilled ISO 45001 process. They attended the
commitment to health and safety should be staff as well as discerning clients, which protects opening and closing meetings with the ISO
etched into the very fabric of any modern the bottom-line as well as the reputation of the 45001 assessor in person, signalling the
company. company. serious]ness with which the company views
My company recently achieved ISO 45001 Rather than it being extra work, we had to standards, procedures and ultimately, safety.
for seven of our Air Separation Units (ASUs) – show the operators that keeping the plants With buy-in from both on-site teams and the
this is the international standard for running goes hand in hand with robust OHS – senior leadership team, it was then a matter of
management systems of occupational health one complements the other. Instead of making sure the safety and quality procedures
and safety (OHS). The experience imposing more procedures and processes, we were easy to follow and accessible, so they are
underscored the critical importance of plant encouraged the plant managers to share their not a burden on anyone’s time. For example,
managers, operators, and engineers in experience, obstacles and pain points with us we saved the generic procedures and risk
informing and supporting a robust and long- so we could resolve them together. This assessments across all sites in one place – an
term approach to OHS. It became clear once consultation and dialogue and coming together easy to access shared site – to standardise
again that in addition to tightening our to find workable solutions was key to these processes and ensure ease of access
procedures, working towards the standard also successfully achieving the certification at all and use.
needed a strategic plan and a communications seven of our Air Separation Units (ASUs) in one Another lesson learnt was that when it comes
push right from the very top to bring all our go – no mean feat. to safety, small changes can have big impacts.
teams on board and get them thinking not just Commitment from senior leadership was For instance, often in this industry, women end
about the what but the why. another crucial component of ingraining the up having to wear men’s safety clothing, rolling
Put simply, high standards of OHS are crucial message of safety-first. Air Products’ up the trouser legs and arms to try and get it to

36 | Plant & Works Engineering www.pwemag.co.uk August/September 2023

 25
Introducing

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life and unrivalled ergonomics combined
with all the advantages of the Combi-CB
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The new COMBi-CB70E electric forklift is the most compact
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Handling & Safety Matters Focus on: Heath & Safety

fit. Working with our supplier to stock a more colleagues – who may not even be
capsule range of female fit and smaller fit fire- directly involved with OHS management.
retardant workwear will ensure that the female Informal engagement such as this
workers are no longer an afterthought. It’s encourages everyone in a business to share
important if we are looking for a more diverse their work, talk about what they find
workforce, that we make them feel welcome, challenging, and where they see opportunities
comfortable, and safe on site while upholding for improvement. From someone who orders
our safety standards at the same time. equipment to the people who install it and
But of course, having achieved what we set make it operational, everyone’s opinion counts.
out to do with ISO 45001 is only half the battle Such casual conversations can often give
won. The harder task is always to maintain the precious insight into what needs tweaking and
certification and not let things slide. And this is how best to go about it.
why a change of mind-sets in important at every In conclusion, it’s quite simple: putting
level of the company because we can’t be lax people’s safety first and ensuring high
– each of us has to make sure we are doing standards may seem a no-brainer but the
our bit so that we are always safe at work and journey to fostering a safety-conscious culture is
audit ready. neither swift nor effortless. It cannot be led by
To promote a culture of inclusivity and shared one team, in isolation. It cannot be imposed by
responsibility the work that goes into the leadership. It is a collaboration where
maintaining safety standards needs to be every team member plays a vital role and
relatable and visible to everyone at the everyone’s voice must be heard, from the CEO
company. This helps everyone know why the and the seasoned plant veterans, right down to
work is important and what’s being done. a rapidly diversifying workforce of newcomers.
Internal social media channels are incredibly
useful for this. Posting often and making sure *Rachel Rawlings is the Regulatory
the content is engaging, alive with images, Affairs and Quality Manager for the UK
personal anecdotes and humour will engage and Ireland at Air Products.

Direct
39_pwe_0923.qxp_Layout 1 08/08/2023 10:56 Page 39

Industry Update

Knockout performance for charity Drill bits get users out of

HI-LINE INDUSTRIES, a UK-based leader in the tight spots
design, manufacture and installation of energy- C.K TOOLS, has announced it has launched the shortest fluted
efficient compressed air purification equipment wood bits on the market. Fast4Access drill bits, just 80mm in
says it is well known for the long-standing length, will allow users to drill through wood to create clean
support it provides to the local sporting and fast holes in limited space. The company says 50% shorter
community in Burton upon Trent. The company is than the existing Fast4 range, and 30% shorter than similar
a main sponsor at both Burton Albion Football products on the market, Fast4Access is ideal when space is too
Club and Burton Rugby Football Club. Now, Hi- tight to drill a hole head on, or accuracy is essential. Designed
line’s Managing Director Steve Smith is adding for tight corners, smaller joists, and jobs where a smooth run is
to this tradition by raising thousands of pounds critical – for example installing pipe through multiple joists –
for Cancer Research UK through his endeavours Fast4Access promises fast, tidy results when drilling into wood.
in White Collar Boxing, a series of high-profile The high-performance drill bits boast a threaded screw tip for
fundraising events organised by Ultra, the UK’s faster drilling speed, and four cutting faces, giving clean,
largest charity sports organisation. accurate holes at speed.
Ultra White Collar Boxing (UWCB) is an w| www.ck-tools.com
opportunity for people to experience the
wonderful world of boxing in a safe and
enjoyable environment, while simultaneously
raising money for Cancer Research UK (CRUK)
and getting into shape. The organisation is a
spin-off of the original White Collar Boxing,
which began in New York in 1988 when two
‘white collar’ workers, a doctor and an attorney,
trained for a few weeks before boxing each Steve Smith and opponent
other at a black-tie event. UCWB commenced Matt Long prior to their
in 2009, becoming a corporate partner of Ultra White Collar Boxing charity fight)
CRUK in 2013. Today, the organisation is one of CRUK’s largest fundraising partners, donating over £25 million to
date. Visit www.pwemag.co.uk for the full release
t| 01283 533377 e| enquiries@hilineindustries.com w| www.hilineindustries.com

Push for fire safety Swift upgrade

with cable TOUCHPATH, an international supply
chain solutions provider has announced it
stripper launch has achieved a swift ERP upgrade to
Microsoft Business Central for user
C.K TOOLS, has announced it has launched a range VADO, a leading bathroom fittings
of cable strippers designed to tackle low smoke zero company. The company says the change
hydrogen (LS0H) cable. Use of LS0H cable is has been enabled by its flexible ‘Touch
increasing as specifiers bid to improve fire safety, but WMS’ system, which now integrates with
stripping this much tougher material is a challenge. ten mainstream ERP systems market-wide.
Now widespread in Ireland and the USA, use of Paul Simpson, VADO IT Manager reports:
LS0H cable is on the rise in the UK. “It has all been very smooth, no retraining
While PVC cable jacketing may be fire resistant, it has been needed and there has been
can generate around 50% its weight in smoke when very minimal disruption to our shopfloor
exposed to high heat or flames. This thick, acrid processes.”
smoke is highly toxic, corrosive, and can damage Commenting on VADO’s ERP upgrade, TouchPath CEO David Myers says: “Touch WMS has been designed for use in
electrical equipment. Toxic smoke inhalation causes complex manufacturing and distribution environments, as it can be easily reconfigured to support system architecture such
more fire-related deaths than fires themselves. As such, as VADO’s new ERP regime.”
many specifiers are opting to replace PVC or other w| www.touchpath.com
cable jacketing with LS0H.
w| www.ck-tools.com
New overhead crane
Bunting has announced a new 12.5-tonne overhead
crane and a pillar mounted slewing jib crane are the
latest investments at its magnetic separator and metal
detector manufacturing facility in Redditch. The new
overhead crane replaces one originally installed in
1989, increasing the lift capacity and improving
manufacturing productivity.
Bunting is one of the world’s leading designers and
manufacturers of magnetic separators, eddy current
separators, metal detectors and electrostatic
separators.
Crane specialist AG Cranes is supplying and installing
both the new single girder overhead travelling crane
and pillar mounted slewing jib crane. The new overhead crane spans the 18-metre width of the main Redditch
manufacturing area with a capacity lift of 12.5-tonnes. The hook path enables lifts up to 8-metres.
w| www.bunting-redditch.com

August/September 2023 www.pwemag.co.uk Plant & Works Engineering | 39

40-41_pwe_0923.qxp_Layout 1 07/08/2023 10:00 Page 40

Special Focus Sustainability & Net Zero

and saving costs. Whilst using RTI is in the

majority of cases far more sustainable than
using single use packaging they were able to
enhance their sustainability by greatly reducing
product damage and waste from damaged RTI.

Streamlining product supply to

assembly stations
While supply chain management is often
thought of as only involving external
companies, improvements can often be made
in the movement of products around your own
premises.
Turck Banner was recently approached by a
prestigious motor manufacturer to supply a
simple light and a switch. When it asked about
the application and business objectives driving
the request, it became obvious that, working in
partnership with each other, Turck Banner could
make huge improvements in the process of
moving product from the main warehouse all
the way to the assembly station. As a result of
implementing the changes, the takt time (time to
produce a finished product) was reduced,
allowing them to increase production, which in

Sustainability turn paid for the changes. The customer also

reduced their internal transport and
maintenance costs, thus improving their

through supply sustainability.

UV Barcoding for invisible traceability

chain management
Even in industries where traceability is not a
legal requirement, it is often becoming a E
W
business requirement, in order to generate the
data required for improving processes and
driving efficiency.
Sustainability doesn’t have to come at a cost, in fact many Barcoding is often a cheap and reliable
companies are finding that their initiatives are saving them method of marking a product for tracking and
traceability. The barcode can be made in a
money. Turck Banner has identified three broad areas where number of ways ranging from Direct Product
they can assist companies in saving costs, as well as becoming Marks (DPM) that are etched or stamped into
the product, to adhesive labels attached to the
more sustainable. These are production efficiency, energy product. The majority of these barcodes are
management and supply chain management. Turck Banner visible to the naked eye and consume space on
illustrated to PWE three different applications in the supply chain the product. Ultraviolet ink is only visible when
illuminated with a blacklight. By using a filter
management category; Returnable Transport Items (RTI), that blocks visible light but allows UV light to
pass, it is possible to print a UV barcode on top
Returnable Transport Items enhanced, which were the primary objectives of a product that already contains printing or
At a distribution centre, maintaining the control of the upgrade. The simple addition of tags to decoration. This facilitates tracking and
of Returnable Transport Items (RTI) was the RTI facilitated the emptied RTI to be traceability with all the associated sustainability
extremely challenging as different suppliers use identified and directed to the allocated storage advantages, without spoiling the aesthetics of a
different RTI. Once the RTI has been emptied it area, based upon the type of RTI and the product or requiring a larger product and
has to be stored before being returned to the supplier. Damaged RTI were also recorded by packaging to accommodate the barcode.
supplier. The distribution centre was upgrading their tag enabling the supplier to easily identify, These are just three examples where careful
its inventory control by using Turck Banner’s repair or remove them. Although RTI are investment in the right products can have a
RFID system, which can read hundreds of tags designed to protect the product that they significant impact on both short- and long-term
almost simultaneously as they pass through a contain during transport, a damaged RTI can savings, at the same time making the product or
gate. In addition to the products having an RFID often be the cause of the product being process more sustainable.
tag, a tag was added to the RTI. The task of damaged.
checking-in product inventory was greatly The distribution centre achieved their primary For further information please visit:
speeded up and product traceability objectives of making themselves more efficient www.turckbanner.co.uk

40 | Plant & Works Engineering www.pwemag.co.uk August/September 2023

FBW25
40-41_pwe_0923.qxp_Layout 1 07/08/2023 10:00 Page 41

Sustainability & Net Zero Special Focus

New larger-output VSRT models 99.75% steam quality.

Like the existing models in the range, the

without compromising efficiency two new models come with the assurance of a
10-year “unparalleled” warranty on the
pressure vessel, double that of the industry

S
ince its launch in 2018, Fulton’s VSRT hour of steam. standard. Additionally, like all Fulton VSRT and
has benefited many users from “In short, what we are delivering with these electric boilers, they contain no refractory and
generous savings in gas and water new models is much higher output versions have no requirement for five-yearly, non-
consumption in addition to CO2 without compromising efficiency.” destructive testing, which contributes to
and NOX emissions. These new, larger-output VSRT models reduced lifecycle costs when compared to
At launch, the seven-model VSRT range was maintain exceptionally high operating standard shell and tube boilers.
available with outputs from 160 to 960 kg/h, efficiencies (up to 86% gross thermal These advanced, energy-saving and
but with demand increasing for an energy efficiency compared to approximately 80% environmentally beneficial features are
efficient boiler with larger outputs like those of from typical boiler designs), which results in standard across the now expanded VSRT
horizontal reverse-flame steam boilers, Fulton is lower operating and lifecycle costs and range. Compared to equivalent vertical
now expanding the range and introducing two improved return on investment. The latest tubeless steam boilers, the VSRT is a more
new re-designed VSRT models with outputs of models also continue to achieve ultra-low durable, and in many cases, compact boiler
1565 and 1956 kg/h. NOx emissions of less than 20ppm and 10:1 that is energy-efficient, produces an increased
Commenting for Fulton, managing director turndown capability. volume of higher quality steam, is easy to
Carl Knight said: “These new models are The water volume of these latest VSRT maintain and backed by an unparalleled
ground-breaking for their output range. When models is far greater than equivalent warranty. Additionally, the VSRT complies with
you consider the VSRT-100 and VSRT-125 horizontal shell and tube boilers and steam the City of London Air Quality Strategy and
models, there are no truly efficient tubeless generators, combined with an impressive MCPD regulations, is constructed to BS EN
vertical steam boilers in the marketplace with steam chest volume giving it the ability to react 12953 and UKCA/CE marked to PED.
similar output ranges, the VSRT is the only quickly to changes in steam demand. The
tubeless boiler available with the capability of VSRT still boasts a start-up time of For further information
efficiently producing nearly two tonnes per approximately 20 minutes and achieves a please: www.fulton.co.uk

EXCEPTIONAL EFFICIENCIES
WITHOUT THE COMPROMISE
Our VSRT range is expanding with the introduc琀on of two
new re-designed and ground-breaking models. With outputs of
1565 and 1956 kg/h, the new VSRT-100 and VSRT-125 are the
only tubeless ver琀cal steam boilers available capable of e ciently
producing nearly two tonnes per hour of steam!

Maintaining excep琀onally high opera琀ng e ciencies of up to

86% gross thermal e ciency (compared to approximately 80% from
typical boiler designs) results in lower opera琀ng and lifecycle
costs and improved return on investment. The latest models also
con琀nue to achieve ultra-low NOx emissions of less than 20ppm
and the 10:1 turndown capabili琀es of smaller VSRT models.

In short, what Fulton is delivering with these new VSRTs is

signi昀cantly higher output versions without compromising
e ciency and performance!

For further informa琀on scan the QR code,

visit www.fulton.co.uk, email sales@fulton.co.uk
or call the o ce on +44 (0)117 972 3322.

FBW255 - VSRT125 Advertisement - PWE.indd 1 19/07/2023 11:02

PWE Web Locator.qxp_Layout 1 01/08/2023 12:01 Page 47

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P&S_Aug_0923.qxp_Layout 1 07/08/2023 09:23 Page 43

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P&S_Aug_0923.qxp_Layout 1 07/08/2023 09:23 Page 44

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P&S_Aug_0923.qxp_Layout 1 07/08/2023 09:23 Page 45

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P&S_Aug_0923.qxp_Layout 1 07/08/2023 09:23 Page 46

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48_pwe_0823.indd 1 01/08/2023 10:33