Case Study: A switch to Mobil DTE 10 Excel hydraulic fluid has helped MPact Polymers reduce the energy used by processing equipment at its Pinetown site by 7%. The move also helped optimise equipment performance, which reduced unscheduled maintenance, while the hydraulic fluid’s long life cut waste oil disposal costs.

A new modelling approach for hybrid bearings gives a more accurate picture of their performance and helps engineers justify their use in the correct application, writes Guillermo Morales-Espejel, Principal Scientist at SKF Research and Technology Development.

The aim of the EU Eco-Design Directive is to improve the environmental impact of energy-intensive products by optimising their design. Since pumps require a lot of energy, some inevitably fall within scope of this directive. Better design could significantly reduce their energy consumption. However, considerably more can be achieved if the pump is not viewed in isolation, but as part of the overall system along with its electric motor and controller.

Jonathan Wilkins, director of industrial automation parts supplier, EU Automation, discusses what manufacturers should consider when choosing which type of robot to invest in.

Southern Manufacturing & Electronics returns to Farnborough between February 11th-13th 2020, and will again include a range of exhibitors spanning the full panorama of engineering activity. PWE reports.

Tobius Antius, CEO of food process automation company Novotek AB, explains how, with automation and systems, manufacturers can help to minimise the creation of food waste in manufacturing.

PWE takes a look at the potential benefits that can be achieved when retrofitting pumps.

When it was first introduced a little over a century ago, the heavy-duty belt conveyor revolutionised the mining, quarrying and cement industries. Maintaining this machinery, however, has always been a slow, expensive and dangerous task. PWE reports.

Staged every three years, PPMA Total Show (1-3 October 2019, National Exhibition Centre (NEC), Birmingham) is the UK’s largest processing and packaging machinery exhibition. PWE reports.

Chris Muscavage, field technical service engineer, at Sulzer, looks at the importance of pump performance testing and how it can improve plant reliability.

Are you taking the risks of hydraulic piston seal failure seriously enough? PWE takes a look at the heavy demands placed on these seals and describes the development of new solutions to overcome their challenges.

In modern paper and cardboard production there are endless dosing tasks, for which precision and high reliability are especially critical. Mindful of these factors, European carton maker Moritz J Weig GmbH is increasingly turning to Qdos peristaltic pumps from Watson-Marlow Fluid Technology Group (WMFTG). PWE reports.

Precision sensor technologies are not only proving their value during the production and testing of wind turbines, but also in the real time condition monitoring of operationally active onshore and offshore wind farms, says Chris Jones, managing director of Micro-Epsilon UK.

Chains are often given little attention as components in machines or logistics systems. For the overall system, however, they are of great importance: without a drive chain the machine will not run, and without conveyor chains the logistics will not work. Chain manufacturer, Renold, offers tips on how to make chains last longer with the help of the correct lubrication.

Progressive cavity pump specialist SEEPEX has developed a new system to improve dewatered sludge handling, enabling long distance transfer with reduced operational costs by using a combination of PC pump technology and dense-phase conveying.

Heat, contamination and unpredictable weather constantly threaten to disrupt the performance of offshore oil and gas facilities. These unforgiving conditions can be detrimental to the performance of drilling equipment, pumps and extraction machinery — but what steps can be taken to ensure quality engineering at sea? Chris Johnson, managing director of SMB Bearings, explains why, sometimes, it’s the little things that count.

It can be a challenge to maintain efficiency in manufacturing processes that rely on rapid temperature change, they are energy intensive and will often form a natural bottle-neck in an overall process. Implementing a new control strategy that is both more accurate and responsive can therefore bring improvements to both productivity and process efficiency. PWE reports.

Finding the most effective solution to upgrade a pumping station can be a complex process. Striking the balance between improved performance and minimised costs requires experience and excellent technical abilities. ECS Engineering Services recently delivered a cost effective refurbishment project for the Environment Agency that initially had some very ambitious costs. PWE takes a closer look.

When selecting sensors for displacement, position, distance and profile measurement tasks, engineers should consider the various types of sensor filtering before making a purchasing decision, says Chris Jones of Micro-Epsilon.

For anyone involved in works management, Southern Manufacturing offers a wide range of relevant products and services, from health & safety solutions, through all kinds of production hardware to management software and consumables.

As we move along the road towards Smart Manufacturing the subject of cyber-security is becoming arguably even more important. Chris Evans, marketing & operations group manager, Mitsubishi Electric Europe B.V. Automation Systems Division, reports.

The new Yokogawa WT5000 is the first of a new generation of precision power analyser that offers measurement accuracy of ± 0.03% combined with stability, noise immunity and plug-in modular flexibility to meet the measurement needs of today’s developers of energy-efficient systems. PWE reports.

Automation has always lent itself to the manufacture of mass produced disposable medical devices and the bulk processing of samples - for two main reasons; initially for speed and repeatability, and then because human presence poses one of the biggest contamination risks in a clean production or processing environment. PWE reports.

Lesley Eaton, business development and marketing manager, SEEPEX, looks at how progressive cavity pumps can overcome the toughest processing challenges.

If damage to bearings can be detected early, the potentially extensive downtime and repair costs arising from failure in service can be avoided. Phil Burge, marketing and communications manager at SKF looks at the tell-tale indicators of bearing wear and puts forward the argument for condition monitoring.

With bearing failures accounting for around 40% of all pump and rotating equipment malfunctions, it’s easy to accept downtime for repair and replacement as simply part of the deal. But there is a quick-gain, low-cost way to maximise pump efficiency and minimise downtime by selecting the appropriate bearing housing seals, says Chris Carmody of AESSEAL.

When selecting a non-contact capacitive displacement sensor, a number of key factors need to be considered, including target size and shape, guarding method and bandwidth. As well as clean environments, the sensors can also operate in dirty, dusty industrial areas too, says Chris Jones of Micro-Epsilon.

Sawyer completes jobs quickly and accurately, works safely alongside co-workers and is an integral part of the workforce. However, Sawyer is not your average employee — he is a robot. Jonathan Wilkins, marketing director at obsolete industrial parts supplier, EU Automation, explains how advances in technology are changing the way that humans interact with robots.

Kieran Doyle, managing director at Oilgear, explores the innate features and processes that can ensure hydraulic pump performance is not simply defined by basic certification, but offers further benefits to the application that reduce the risks of downtime.

By withstanding contaminated and poorly lubricated conditions, hybrid bearings are less prone to surface distress than their all-steel counterparts. Phil Burge, marketing and communications manager at SKF explains the structure and materials of hybrid bearings and how these features help extend machine service life.

Alex Myers, retrofit sales director at Sulzer, looks at the latest technology for improving efficiency and reducing operating costs.

Southern Manufacturing & Electronics returns to Farnborough from February 6-8th 2018 for its 20th anniversary event. PWE reports.

The evolution of asset security definition means a multi-faceted approach is needed. PWE reports.

Refinery operators have a pressing requirement to improve the efficiency of flow control in their plants and they want to know from the Distributed Control System (DCS) if valves are open or closed. In a typical refinery, 10% of valves are actuated and 90% are manually operated. This poses a serious problem for end-users if the DCS does not accurately know how many manual valves are opened or closed, which limits the efficiency of their business operations.

Bredel 65 hose pumps from Watson-Marlow Fluid Technology Group are now providing constant efficiency in ball-milling processes at a high-volume battery plant in China. PWE reports.

A motor control centre (MCC) sits at the heart of an industrial plant. If well maintained, an MCC can last for decades, but despite their sturdiness, even the most reliable MCCs have to be retired at some point. Pat McLaughlin, operations director of Boulting Group, explains the early warning signs that an MCC needs replacing. There are several reasons for replacing an MCC, but the most common ones include obsolescence, incompatibility with new legislation or the condition of the MCC deteriorating. Technological advancements that allow the design of intelligent, more efficient MCCs are another reason why companies sometimes opt for an upgrade.

Climate control of enclosures using water cooling is highly efficient, especially if there is already a central cold water supply available in the production plant. The new Hygienic Design air/water heat exchangers from Rittal are ideally suited to the food industry, where hygiene standards are exceptionally stringent. PWE reports.

Forklift trucks need fast and easy access to and from premises, taking goods and pallets out to, or bringing them in from, delivery vehicles. Maximum transport efficiency would be afforded simply by a hole in the wall; but of course there are security considerations and the need to prevent heat/cold transfer. Naturally, then, there are doors, and for every door there is an ideal door control system. Paul Rudge of sara LBS examines the various choices, and highlights the advantages, disadvantages and installation requirements for each.

Jonathan Walker, engineering manager at Oilgear, explores the innate features and processes that can ensure hydraulic pump performance is not simply defined by basic certification, but offers further benefits to the application that reduce the risks of downtime.

Accurate dosing pumps are enabling Welsh Water to maintain strict phosphorus limits and reduce maintenance costs. PWE reports.

Large pumps have generally been designed to perform for decades, making them a valuable asset that requires periodic maintenance. When the performance of an older pump begins to deteriorate, it may be a sign that the impeller is worn or the volute has become corroded, and by the time this happens, finding new parts can be a considerable challenge. Fortunately, modern design techniques and manufacturing processes can create a vast range of components using reverse engineering. Jesse Jackson, customer services manager at Sulzer's Mobile Service Center in Alabama, looks at what can be done to resurrect an ageing pump asset.

If there’s one thing that continues to hamper the UK manufacturing sector, it’s the ongoing struggle for greater productivity. As many factories are turning to capital equipment and modern machinery in an effort to speed up production lines and improve worker output, drive technology is becoming critical to enabling better plant automation, ensuring maximum productivity, and reliability throughout the entire production cycle. Marcus Schneck, CEO at norelem UK, looks at the importance of standard components in drive technology.

Industrial processes across the globe require pumps to operate reliably and efficiently. The latest pump designs and coating technologies offer significant improvements in the long-term performance of industrial pumps. By minimising the effects of corrosion and erosion, users can enhance productivity and reduce running costs. PWE reports.

While variable speed drives (VSDs) provide an important energy saving technology, Mitsubishi Electric’s Matt Handley questions how many of the installed base of drives are actually set up to run at their maximum efficiency.

Hannover Messe 2016 had a clear message: integrated industry has well and truly reached the mainstream. To prove its point, the show featured over 400 application examples of fully digitalised processes for the manufacturing and energy industries. The fourth industrial revolution, it seems, is well underway. However, to ensure that the factories of the future don’t remain castles in the air, it is necessary to shine a stronger spotlight on the benefits for industry, employees and society in general. This is precisely what the organisers of Hannover Messe 2017 (24–28 April) say it will do. PWE reports.

Hannover Messe 2016 had a clear message: integrated industry has well and truly reached the mainstream. To prove its point, the show featured over 400 application examples of fully digitalised processes for the manufacturing and energy industries. The fourth industrial revolution, it seems, is well underway. However, to ensure that the factories of the future don’t remain castles in the air, it is necessary to shine a stronger spotlight on the benefits for industry, employees and society in general. This is precisely what the organisers of Hannover Messe 2017 (24–28 April) say it will do. PWE reports.

Heat recovery should be a serious consideration for any business running a compressed air system. Andy Jones, managing director at Mattei, talks through the options.

Factories, warehouses and other ‘shed’ type buildings provide special challenges for HVAC systems. Eduard Kovac of Hoval explains how decentralised ventilation units can meet many of these challenges.

Ken Revell, Business Line Manager Sales & Marketing for Atlas Copco’s Compressor Technique Service Division, looks at how small parts can make a big difference to production equipment performance and reliability.

When it comes to specifying pumping equipment, many companies, particularly those under increasing pressure to cut costs, could actually be making decisions that will cost them more in the long run. Steve Schofield, director and chief executive of the British Pump Manufacturer’s Association (BPMA), explains how lifecycle costing can help to reveal the true cost of a pump.