NEWS | FEATURES | PRODUCTS | CASE STUDIES Feb/March 2025| Issue 485 www.pwemag.co.uk @PWEmagazine1 Enhancing efficiency in burner technology Inside this issue: 16 > Driving AI accessibility for predictive maintenance 32 > Dispelling common myths about OAS in warehouse operations 36 > Apprenticeship programme opens engineering opportunities page 28 @plant-&-works-engineering PWE Plant & Works Engineering Since 1981
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It is crucial for the government to balance thorough planning with the immediate need for clear policy direction. The UK Industrial Strategy can’t wait The recent announcement that the Government will delay the release of its comprehensive industrial strategy until June has caused mixed reactions from industry stakeholders and policymakers. This postponement, aligning the strategy’s publication with the upcoming spending review, aims to provide a cohesive framework for the UK’s economic future. In the interim, Labour plans to roll out specific sectoral strategies, notably in life sciences and advanced manufacturing, to maintain business confidence and address immediate industry concerns. Industry leaders have expressed concerns that the absence of a detailed, long-term industrial strategy Editor’s Comment ‘ ’ may deter significant investments. Stephen Phipson, Chief Executive of Make UK, highlighted only last year that major international manufacturers are withholding investments in the UK pending clearer policy direction. He emphasised the urgency, stating, “Industrial strategy is so urgent, we need this tomorrow.” The delay also raises questions about regional development and infrastructure investment. Recent critiques have pointed out disparities in funding allocations, with significant investments favouring projects in the South, such as the £6bn Lower Thames Crossing, while essential northern infrastructure, like the Tyne Bridge restoration, faces funding shortfalls. This situation underscores the necessity for a balanced and timely industrial strategy that addresses regional inequalities and fosters equitable economic growth. While the need for a wellconsidered and comprehensive strategy is paramount, the current economic climate—with potential recession risks and ongoing global uncertainties—demands prompt and decisive action. Delaying the strategy’s release may inadvertently prolong uncertainty, potentially hindering investment and innovation. Therefore, it is crucial for the government to balance thorough planning with the immediate need for clear policy direction, ensuring that the UK’s industrial sectors are equipped to navigate current challenges and seize emerging opportunities. While the development of a robust industrial strategy necessitates careful deliberation, accelerating its release could provide the clarity and confidence required by businesses and investors. Such a move would not only address pressing economic concerns but also demonstrate a commitment to proactive leadership in shaping the UK’s industrial future. February/March 2025 www.pwemag.co.uk Plant & Works Engineering | 03
PORTABLE 1 TONNE GANTRY CRANE 1000 KG CWGC1000 Tough steel construction ‘I’ beam cross member for added strength ADJUSTABLE HEIGHT 25203600mm PRICE CUT WAS £622.80 inc.VAT £598.80 inc.VAT £499.00 exc.VAT See online for included accessories IMIG100NG MIG WELDERS Quality machines from Britain’s leading supplier Model Min/Max Amps Order Code exc.VAT inc.VAT MIG103NG 35-90 010115615 £134.99 £161.99 IMIG100NG 40-100 010115610 £149.98 £179.98 FROM £161.99 inc.VAT £134.99 exc.VAT SEE FULL RANGE OF ARC ACTIVATED HEADSHIELDS IN-STORE/ONLINE VENTILATORS & EXTRACTORS Model Fan Diam. 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Output kW Order Code exc.VAT inc.VAT Little Devil II 10.3 010416020 £89.98 £107.98 Devil 700 15 010410182 £114.99 £137.99 Devil 900 24.9 010410186 £159.98 £191.98 Devil 1600 36.6 010410190 £189.98 £227.98 Devil 2100 49.8 010410194 £249.00 £298.80 Devil 4000 131 010414000 £479.00 £574.80 DUAL VOLTAGE IN STOCK FROM £203.98 inc.VAT 230& 110 VOLT PROPANE GAS FIRED LITTLE DEVIL II FROM £107.98 inc.VAT £89.98 exc.VAT DRILL PRESSES Range of precision bench & floor presses for enthusiast, engineering & industrial applications CDP102B Model Motor (W) Speeds Order Code exc.VAT WAS inc.VAT inc.VAT CDP5EB 350 / 5 060712030 £94.99 £119.94 £113.99 CDP5RB 350 / 5 060710035 £94.99 £119.94 £113.99 CDP102B 350 / 5 060715512 £109.98 £139.14 £131.98 CDP152B 450 / 12 060715522 £179.00 £250.80 £214.80 CDP452B 550 / 16 060715575 £299.00 - £358.80 CDP352F 550 / 16 060715562 £319.00 £394.80 £382.80 CDP502F 1100 / 12 060715592 £689.00 £838.80 £826.80 B = Bench mounted F = Floor standing PRICE CUT NOW FROM WAS £119.94 inc.VAT £113.99 inc.VAT £94.99 exc.VAT Top quality belt driven air compressors for industrial & commercial users inc; garages, factories, workshops and farms. 10 bar/150psi max working pressure †V-Twin *230V XEV16/100 Model Air. disp Air RCVR Order Code exc.VAT inc.VAT XEV16/100 (OL)‡* 14cfm 100ltr 000112270 £589.00 £706.80 XEV16/150 (OL)‡* 14cfm 150ltr 000112272 £659.00 £790.80 XEV16/200(OL)‡* 14cfm 200ltr 000112274 £719.00 £862.80 XEV16/150(400V)‡ 14cfm 150ltr 000112276 £699.00 £838.80 XE37/270 (OL)* 36cfm 270ltr 000112370 £1459.00 £1750.80 INDUSTRIAL AIR COMPRESSORS FROM £706.80 inc.VAT £589.00 exc.VAT MMA200A AT165 MMA & ARC/TIG INVERTER WELDERS Model Min/Max Output Current Electrode Dia. (mm) Order Code exc.VAT inc.VAT MMA140A 20A-140A 1.6-3.2 010112161 £104.99 £125.99 MMA200A 20A-200A 1.6-3.2 010112163 £139.98 £167.98 AT165 10A-160A 2.5/3.2/4.0 010112149 £219.98 £263.98 FROM £125.99 inc.VAT £104.99 exc.VAT HEAVY DUTY SUBMERSIBLE WATER PUMPS Model Max Flow Max Head Order Code exc.VAT inc.VAT PSV3A# 133L 8M 051016042 £49.98 £59.98 PSV5A# 217L 8M 051016046 £59.98 £71.98 HIPPO 2 230V 85L 6M 051010190 £69.98 £83.98 PSV4A# 216L 8M 051016044 £59.98 £71.98 PVP11A‡# 258L 11.0M 051016060 £89.98 £107.98 HSEC650A# 290L 9.5M 051011650 £249.00 £298.80 #Auto ON/OFF float switch on these models ‡Sewage cutter pump FROM £59.98 inc.VAT £49.98 exc.VAT Built for tough daily use in automotive/industrial workshops * Available with/without 7 pce pin, bracket & pressing plate kit # Economy model HYDRAULIC PRESSES PROFESSIONAL QUALITY Model Order Code exc.VAT inc.VAT CSA4B-4 tonne bench# 020413025 £169.98 £203.98 CSA10EP 10 tonne bench* ‡ 020414025 £189.98 £227.98 CSA12F 12 tonne floor*# 020413020 £379.00 £454.80 CSA20FBT 20 tonne floor 020414058 £489.00 £586.80 CSA30FPB 30 tonne floor 020415201 £959.00 £1150.80 CSA50FPB 50 tonne floor 020415203 £1699.00 £2038.80 CSA30FP FROM £203.98 inc.VAT £169.98 exc.VAT ‡ WAS £233.99 inc.VAT HYDRAULIC LIFTING TABLES Model Max. 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February/March 2025 www.pwemag.co.uk Plant & Works Engineering | 05 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 t| 01732 370342 e| damien.oxlee@dfamedia.co.uk Sales Manager: Sara Gordon t| 01732 370341 e| sara.gordon@dfamedia.co.uk Sales Manager: Andrew Jell t| 01732 370347 e| andrew.jell@dfamedia.co.uk DFA Direct: Damien Oxlee t| 01732 370342 e| damien.oxlee@dfamedia.co.uk Production Manager & Designer: Chris Davis e| chris.davis@dfamedia.co.uk Marketing Manager: Hope Jepson e| hope.jepson@dfamedia.co.uk Reader/Circulation Enquiries: Perception t| +44 (0) 1825 701520 e| cs@perception-sas.com Financial: Finance Department e| accounts@dfamedia.co.uk Managing Director: Ryan Fuller e| ryan.fuller@dfamedia.co.uk Published by: DFA Media Group 192 The High Street, Tonbridge, Kent TN9 1BE t| 01732 370340 e| info@dfamedia.co.uk w| www.pwemag.co.uk Official Supporters: Printer: Warners, UK © Copyright 2025, DFA Manufacturing Media Ltd ISSN 0262-0227 PWE is a controlled circulation magazine, published 11 times a year. 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 and newsletters do not necessarily express the views of the Editor or publishers. The publishers accept no legal responsibility for loss arising from 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. COMMENT 3 NEWS 6 A round-up of what’s happening in industry. SMART MANUFACTURING WEEK 2025 10 INSIGHT 12 MAINTENANCE MATTERS - INCORPORATING PROBLEM SOLVER 14 Focus on: Condition Monitoring/ Smart Maintenance Conveyor belt roller bearings are essential for maintaining industrial operations. Their failure can lead to significant disruptions, but early detection methods, such as acoustic imaging, offer a way to identify issues before they escalate. PROCESS, CONTROLS, & PLANT 20 Focus on: Compressed Air/ Pumps & Valves Compressed air is a proven source of reliable and sustainable power for industrial operations. Now, with technologies such as remote monitoring and AI optimisation, it is set to enter a new era of performance and efficiency. ENERGY & ENVIRONMENTAL MANAGEMENT 28 Focus on: Boilers, Burners & Controls/ HVAC Optimising industrial burner technology enhances efficiency, reduces emissions, and cuts costs. Through advanced modulation, fuel flexibility, and digital monitoring, businesses can achieve significant energy savings while meeting sustainability and regulatory goals. PWE reports. HANDLING & SAFETY MATTERS 32 Focus on: Handling & Storage As warehouses face growing demands for faster order fulfilment, many are turning to digital solutions like Operator Assist Systems (OAS) to improve productivity and safety. SPECIAL FOCUS 36 Skills & Training/ Robotics/ Factory Operations PRODUCTS & SERVICES DIRECTORY 42 Contents 12 32 14 28 BCAS official media partner
News 6 | Plant & Works Engineering www.pwemag.co.uk February/March 2025 Britain’s manufacturers believe the introduction of a formal industrial strategy will significantly boost investment, improve productivity, and help address future skills needs, according to a recent major survey. The findings are drawn from the annual Make UK/PwC Senior Executive survey, which captures the views of senior manufacturing executives on the opportunities, risks, and challenges they face in the year ahead, as well as their outlook for the UK and global economies. The survey highlights manufacturers’ optimism about the benefits of an industrial strategy, despite challenges such as rising costs and the threat of a trade war. A majority of manufacturers see the UK as a competitive place to produce goods, with nearly two-thirds (63%) stating that the opportunities for their businesses in 2025 outweigh the current risks. However, the survey also reveals a divided view on the UK economy, with as many executives expecting it to deteriorate as improve by 2025. In response to these mixed economic signals, manufacturers are demonstrating resilience by prioritising innovation, upskilling, and market expansion. Many companies are turning to new technologies and automation as a means of mitigating rising costs and improving operational efficiency. Make UK is now calling on the Government to urgently detail its plans for a long-term industrial strategy following recent consultations, arguing that such a strategy is crucial to sustaining business confidence and strengthening the relationship between industry and government. Stephen Phipson, Chief Executive of Make UK, said: “Manufacturers have demonstrated their resilience over and over again in recent years and, despite the numerous challenges they face, those that remain innovative and are prepared to invest in new technologies, expanding markets and, most crucially, their people will continue to thrive. But, they can only do this if they are operating in the most favourable business environment and there is little doubt that the next twelve months are set to be immensely challenging in a complex international environment. “To help companies navigate a way through these challenges it is now vital that Government sets out as a matter of urgency the immediate and significant priorities as part of its formal industrial strategy given the very clear benefits manufacturers believe this will bring. By doing this, it will help re-boot business confidence and ensure the year gets off on a positive footing in terms of the relationship between industry and Government.” Cara Haffey, Leader of Industrials and Services at PwC UK, added: “While it’s true that UK manufacturers are navigating a complex business landscape – compounded by rising costs – there’s a palpable sense of optimism and resilience underpinning the sector’s trajectory for 2025. This optimism is fuelled by hopes of increasing clarity on the proposed UK industrial strategy, as well as a decisive shift towards technology adoption. The sector is moving from viewing technology as a source of incremental improvements towards acknowledging its power to transform operations. “Additionally, there’s a strong focus on innovation, with companies investing in new product lines and business development to seize growth opportunities. This approach, alongside efforts in product development, upskilling, cost management, and embracing technology, positions manufacturers well to navigate challenges and contribute significantly to national economic growth.” According to the survey, over half of manufacturers (57%) said they would increase investment if a long-term industrial strategy were introduced. Additionally, 43% believe such a strategy would drive productivity improvements, while 42% see it as key to addressing future skills needs. Despite significant pressures, the survey shows that almost half of companies (49%) regard the UK as a competitive manufacturing base, compared with just a quarter who disagree. Moreover, 78% of manufacturers are developing new products, nearly half are deploying new technologies, and over a third (37%) are planning to expand into new markets. However, challenges remain, with the overwhelming majority of companies (92%) expecting employment costs to rise. Additionally, over three-quarters (76%) anticipate increases in other business taxes, while 72% foresee rising logistics and transport costs. Make UK is urging the Government to ease the burden of these cost increases by reducing business rates and introducing further measures to support decarbonisation and energy efficiency. UK Manufacturers see industrial strategy as ‘game changer’ for investment and productivity PEMAC, a leading provider of cloud-based computerised maintenance management software (CMMS) has announced it has joined the Elecosoft group which specialises in software solutions for the building lifecycle. The companies say this collaboration brings together two complementary solutions, enhancing PEMAC’s ability to support Irish and international customers in optimising asset management and maintenance processes across industries including life sciences, healthcare, and manufacturing. PEMAC says the partnership with Elecosoft underscores its commitment to delivering innovative, integrated software solutions that PEMAC joins Elecosoft to enhance asset management and digital transformation solutions
News February/March 2025 www.pwemag.co.uk Plant & Works Engineering | 07 drive productivity, safety, and compliance. PEMAC, headquartered in Cork with offices also in Dublin, provides CMMS solutions to over 100 blue-chip international companies, with particular strength in life sciences and healthcare, which account for 42% of its revenues. Notable customers include Coca Cola, Gyproc, Heineken, Wyke Farms, Keppel Data Centres, Stryker, SteriPack Group, LumiraDx, and Amgen. The partnership with Elecosoft’s ShireSystem complements PEMAC’s existing PEMAC ASSETS CMMS platform, combining two powerful solutions to meet the growing demand for digital transformation of asset management in Ireland and internationally. PEMAC’s focus on regulated sectors like life sciences, pharmaceuticals, and healthcare aligns with Elecosoft’s strategy to support industries that require high levels of compliance and efficiency. Adrian Whyte, PEMAC Operations Director, commented: “We are incredibly excited to join forces with Elecosoft and become part of their growing global presence. This partnership presents a fantastic opportunity to expand our reach, offering our innovative CMMS solutions to even more businesses in Ireland and beyond. With Elecosoft’s resources and expertise, we look forward to strengthening our service offerings and helping more organisations improve their asset management and operational efficiency. We’re also excited about the potential for increased future investment in PEMAC from the international Eleco Group.” Jonathan Hunter, Chief Executive Officer of Eleco, added: “We are excited to welcome PEMAC, a highly respected Irish company comprising an accomplished and talented team, into the Eleco family. PEMAC’s strong reputation in Ireland and its deep relationships with local clients are key to accelerating our growth in the region. Together with our building lifecycle software brand, Elecosoft, this acquisition enables us to offer even more advanced asset management solutions to Irish businesses, helping them increase productivity, safety, and compliance. “Ireland is an attractive market for Elecosoft as it already services many well-known construction and manufacturing businesses, and we’re excited to expand our presence here as digital transformation continues to drive productivity, safety and compliance. This acquisition not only strengthens Eleco’s capability but allows it to positively contribute to the development of Ireland’s PropTech industry.” Hannover Messe 2025 to Showcase Advancements in Smart Manufacturing and AI Hannover Messe 2025 (31 March – 4 April) will highlight the latest advancements in smart manufacturing, with a strong focus on automation, artificial intelligence (AI), and sustainability. The event’s Smart Manufacturing exhibition area will span seven halls, featuring companies from around the world demonstrating cutting-edge technologies, components, and integrated Industry 4.0 solutions designed to enhance production efficiency and global competitiveness. The exhibition will cover key topics such as automation, sensor technology, robotics, logistics automation, and drive and fluid technology. AI is expected to play an increasingly significant role in manufacturing innovation. Hubertus von Monschaw, Global Director of Trade Fair and Product Management at Deutsche Messe, stated: “Artificial intelligence will revolutionise the entire value chain of manufacturing companies, significantly boosting their competitiveness. Visitors to Hannover Messe 2025 will gain insights into available and upcoming applications in the market.” Exhibitors in the Smart Manufacturing area will include a diverse range of international corporations, small and medium-sized enterprises (SMEs), and startups. The exhibition will provide insights into industrial sensors, electric drives and controls, AI-supported engineering, and integrated solutions for various industries. Attendees will have the opportunity to explore how these technologies can enhance production processes, balancing productivity with sustainability. The Application Park at Hannover Messe will feature robotics applications, with AI-enabled robots demonstrating their ability to learn tasks and adapt dynamically to changing production environments. Such innovations are particularly beneficial for custom-made products and smallbatch manufacturing, enhancing efficiency and flexibility. Drive and fluid technology, traditionally showcased in odd-numbered years at Hannover Messe, will once again be a key focus in 2025 under the Motion & Drives label. Exhibiting companies will present the latest advancements in intelligent and sustainable production technologies. In addition to the exhibition, Hannover Messe will feature a comprehensive supporting programme. The Smart Manufacturing area will host the Industrie 4.0 stage and the Motion & Drives conference stage, both of which are expected to attract significant interest from industry professionals.
News 08 | Plant & Works Engineering www.pwemag.co.uk February/March 2025 As we approach the Spring, with a new President in the US and a UK Government almost a year old, 2025 is proving to be no less challenging than recent years. But, despite the current challenges from escalating costs and a potential trade war, according to Make UK’s latest Senior Executive survey a majority of manufacturers believe that overall, the UK remains a competitive place in which to manufacture and the opportunities for their business in 2025 far outweigh the current risks. In response, the survey shows manufacturers are backing their belief in the UK as a place to manufacture with a significant emphasis on developing new products, entering new markets and upskilling and retraining staff. The survey also gives credence to the view of some Economists that companies will counter the impact of increased costs by investing in new technologies and automation to improve their efficiency. To back the investments companies are making Make UK is now urging Government to set out in detail as soon as possible the full proposals of a formal long term industrial strategy, something which is expected alongside the Government Spending Review in June. The survey is quite clear on the benefits such a strategy will bring, with more than half of companies saying they will increase investment in response to a long term industrial strategy. In addition, more than four in ten companies believe such a strategy will lead to increased productivity and a similar number say it will help them secure the skills they need for the future. The survey also shows that, despite the challenges companies are facing at home and abroad, almost half of companies believe the UK remains a competitive place to manufacture compared to a quarter who disagree. In addition, almost two thirds of companies believe the opportunities for their business in 2025 outweigh the risks compared to just over one in ten who disagree. However, despite these positive intentions, as many companies think the UK economy will deteriorate in 2025 as improve, while the challenges of increased costs are severe. Over nine in ten companies think their employment costs will increase, more than three quarters think the costs from other business taxes will increase and a similar number expect their logistics and transport costs to increase. In response, Make UK will be stepping up its efforts to ensure Government looks at measures to mitigate these increases by reducing business rates in particular, as well as measures and incentives to aid decarbonisation and energy efficiency. By MAKE UK chief executive, Stephen Phipson MAKE uk - the manufacturers’ organisation monthly news comment The British Compressed Air Society (BCAS) has launched a new apprenticeship pack, to guide employers, apprentices and their parents throughout the process. Included in the pack is a new best practice guide for employers, to support the recruitment, management, and development of apprentices in the compressed air and vacuum industry. The guide offers comprehensive advice on apprenticeship structures, recruitment strategies, mentoring, and legal obligations, helping businesses attract and nurture new talent. It highlights the importance of paid apprenticeships, structured induction processes, and safeguarding measures, ensuring apprentices receive the best possible start to their careers. In addition, a handy guide for apprentices explains the areas to consider when choosing an apprenticeship and what to expect during studies. Plus, there is a step-by-step overview for parents and guardians that are keen to support their child to get the best out of their new career. BCAS, alongside its members and the Institute for Apprenticeships and Education BCAS launches new compressed air industry apprentice pack (IfATE), was instrumental in the development of a dedicated compressed air and vacuum industry apprenticeship, an industry first. The industry-specific pathway has already helped the next generation of skilled professionals, providing standardisation of their skills, competence, behaviours and safe working. The standard ensures that upon successful completion, the apprentice achieves a national apprenticeship, academic qualifications and may apply for the professional recognition of EngTech with The Society of Operations Engineers. However, as Terry Collier, Learning and Development Officer at BCAS explains, many businesses, especially those new to recruiting apprentices are keen to receive extra support. He said: “Many of our BCAS members are smaller SMEs that do not have access to large HR departments to assist with recruitment and training. At the same time, these members have a highly skilled workforce made up of professional engineers that have a vast amount of knowledge and experience. There is a real desire to pass this expertise onto the next generation, especially to help address the continuing engineering skills gap. “Our new apprenticeship pack has been launched to help our members, and the wider compressed air engineering community achieve precisely this. A key focus is on workplace integration, with guidance on creating a structured work plan, assigning meaningful tasks, and providing effective mentorship. “In addition, our accompanying apprentice and parents’ guides provide practical, friendly advice during this key stage in a young person’s career.” The guide also outlines the recent government funding changes, including full funding for small and medium enterprises (SMEs) and increased flexibility in Apprenticeship Levy transfers.
Organised by 4 - 5 June 2025 | NEC Birmingham Part of What’s driving the next wave of industrial innovation? At Drives & Controls 2025, five key topics lead the way: Motion Control Robotics & Automation Power Transmission Machine Safety Energy Efficiency Explore these crucial themes across our 8 content theatres this June at the NEC. smartmanufacturingweek.com
10 | Plant & Works Engineering www.pwemag.co.uk February/March 2025 Smart Maufacturing Week Building on the success of the 2024 event, which attracted 13,500 visitors as well as more than 450 exhibitors and 200 speakers and was named Best Tradeshow at the Conference & Events Awards 2024, SMW 2025 is poised to deliver an even larger, more ambitious, and more transformative event, with more international manufacturers and engineers expected to visit this year. Free visitor registration is now open and a limited number of Premium Plus Visitor passes are available to be purchased. To register visit: https://bit.ly/4iy8LxT Reflecting on the 2024 event, Malcolm Greenhill of Charter Controls, said: “This is the best exhibition we’ve ever done, and I’ve been participating in exhibitions at the NEC since 1983.” Charter Controls returns to SMW in 2025 as a Platinum Partner, underscoring its trust in the event. Emphasising the ‘must see’ nature of the event is the presence of prominent exhibitors including Schneider Electric, FANUK UK, 3M, Epicor, Binder UK, Cembre, Charter Controls, Ericsson, Hoffmann Group and ifm Electronic. Alongside other big names the exhibition floor will showcase the most influential players in industry. Amongst these giant technology players are cutting-edge startups and the innovative small businesses set to revolutionise the sector. At the heart of Smart Factory Expo, Innovation Alley will feature emerging manufacturing technologies with exhibitors across four key categories: ‘People’ focusing on Wellbeing, Workforce Management, Recruitment and Training and Skills, ‘Product’ which centres in on Design, R&D and Materials, ‘Process’ which includes Productivity, Resilience, Supply Chain and AI and ‘Planet’ which encompasses NetZero, From factory floor hacks to future trends: Smart Manufacturing Week 2025 The NEC Birmingham will once again play host to Smart Manufacturing Week (SMW) the UK’s largest festival of advanced manufacturing and engineering on 4–5 June 2025. SMW brings together a powerful lineup of events, including Smart Factory Expo, Maintec, Drives & Controls, Design + Engineering Expo and the Air-Tech and Fluid Power and systems zones. PWE reports.
Smart Maufacturing Week February/March 2025 www.pwemag.co.uk Plant & Works Engineering | 11 Sustainability and Energy Management. Following the success of 2024, where attendees engaged with groundbreaking solutions from the next wave of tech and consultancy businesses, the 2025 event will provide opportunities to meet start-ups and early-stage companies and their founders, uncovering transformative technologies that promise to shape manufacturing over the next decade. Visitor Trails offer an exciting way to explore the vast show floor, guiding attendees to the most relevant exhibitors and must-see presentations. From Automation & Robotics to Sustainability, Industrial Data & AI, and Product Innovation & Design these thoughtfully curated pathways make it easy to navigate the show and ensure visitors won’t miss out on what’s important. The free educational programme is comprehensive with seven solutions theatres dedicated to addressing a wide array of topics including; Digital Transformation, Industrial Data & AI, IIoT & Connectivity, Design & Innovation, Automation & Robotics, Leadership & Strategy and Maintenance. New this year is the Technology Showcase Theatre, where visitors can see and get their hands on an array of cutting-edge innovations. Offering a rare glimpse into future developments and prototypes, the theatre will feature everything from advanced robotics to wearable technologies, bringing the next generation of breakthroughs to life. In addition, SMW 2025 will continue its commitment to inspiring the next generation of engineers and manufacturers through its dedicated STEM Programme, sponsored by returning Platinum Partner FANUC. Now extended to focus on school year students, as well as those in further education, hundreds of students and apprentices will have the chance to interact directly with industry experts, offering a hands-on introduction to the exciting world of advanced manufacturing and engineering. As in previous years 2025 will also play host to several satellite events, such as The Manufacturer Top 100 Awards and the Manufacturing Digitalisation Summit. This two-day conference for senior leaders, which attracts many of the top 250 manufacturers from across the UK, is focussed on the application of digital technologies to enhance the processes, efficiencies, and outcomes of the manufacturing industry. On the fun side the much-loved Guitar Legends competition will make a return – with a 3D printed guitar to be awarded to the winner - and adding to the festival atmosphere, The Shadow Monkeys will return with their signature high energy and crowd-pleasing hits to close out the first evening’s visitor party. For those with entrepreneurial ambitions, this year’s event introduces an exciting new feature: ‘Smart Tank’. Designed to inspire and empower budding innovators, this platform invites entrepreneurs to pitch their business ideas and product concepts to a panel of industry experts. Additionally, event attendees can explore the dedicated tech demo area, where innovative solutions will be showcased, offering a detailed look into some of the most exciting developments in technology. Smart Manufacturing Week continues to prioritise sustainability, returning as a carbonneutral event in 2025. In collaboration with Forest Nation, the organisers have pledged to plant one tree for every attendee, a practice introduced in 2023 that has helped reduce the event’s environmental impact while supporting global reforestation efforts. “Smart Manufacturing Week 2025 is laser focused on the visitor experience while ensuring exhibitors have the best opportunity to connect with their target customer base. We create a festival type atmosphere that is entertaining as well as a fantastic opportunity to connect businesses, encourage innovation, and create a platform for industry-shaping conversations.” said Managing Director, Grace Gilling. Smart Manufacturing Week will be taking place at Birmingham’s NEC on the 4th and 5th of June 2025. Other exhibitions are also taking place at the NEC at the same time, and these include Automechanika run by Messe Frankfurt; Med-Tech Innovation Expo and TCT 3Sixty from Rapid News Group and Subcon from the Mark Allen Group. One visitor badge provides access to all events. Register now for free to secure your place at the UK’s most anticipated manufacturing event of the year: https://bit.ly/4iy8LxT For more information and updates, please visit: www.smartmanufacturingweek.com
12 | Plant & Works Engineering www.pwemag.co.uk February/March 2025 Insight In an industry defined by precision and rapid technological advancements, the pneumatics and hydraulics sector recognises the importance of its most vital asset: its people. For Anthony Smith, Managing Director of Metal Work Pneumatic UK, success lies in balancing technical expertise with a culture of collaboration and trust. As the UK subsidiary of the Italian industrial automation manufacturer Metal Work S.p.A., the company has grown into a key player in the pneumatics automation landscape, driven by a forward-thinking ethos and a commitment to customer-centred innovation. In an open conversation, Smith shared his insights into Metal Work’s evolution, the challenges of an increasingly competitive market, and the strategic investments positioning the company for long-term success. A strategic investment in people and place Since its establishment in 1983, Metal Work Pneumatic UK has evolved from a modest importer of pneumatic components into a cornerstone of the Metal Work Group’s global operations. Based in Milton Keynes, the company’s purpose-built facility grew beyond its logistical roots and became a hub for bespoke systems and customer engagement. Recent investments underscore the importance of this location. Metal Work UK is enhancing its capabilities with the development of a new facility designed to meet rising demand and solidify its role as an innovation hub. At the end of 2023 the company moved to its new premises on Featherstone Road in Milton Keynes: “Our Milton Keynes site is not just a warehouse; it’s the heart of our UK operations,” explained Managing Director Anthony Smith. “This investment will allow us to expand our offering, create more bespoke solutions, and engage with customers in entirely new ways.” Central to this expansion is a dedicated customer engagement centre, where clients can experience the latest technologies and explore customised solutions firsthand. “Seeing is Driving pneumatic innovation in automation Anthony Smith, Managing Director of Metal Work Pneumatic UK, discusses with PWE’s Aaron Blutstein the enduring role of pneumatics amid the rise of AI and robotics. With a strong focus on people, innovation, and customer collaboration, the company’s new Milton Keynes facility expands its capacity for bespoke solutions, while leveraging AI to enhance the customer experience and strengthen its people-centric approach. believing,” Smith said. “By creating an environment where customers can experience our capabilities up close, we’re fostering a deeper level of trust and collaboration.” This focus on collaboration reflects Metal Work Pneumatic UK’s integral role within the larger Metal Work Group, a global enterprise with roots in Italy and a vision of growth driven by purposeful innovation. Under Smith’s stewardship, the UK operation has flourished, showcasing how strategy and ethos can align to drive meaningful impact. Recent acquisitions further demonstrate this vision. The addition of AR Vacuum brought niche automation expertise into the fold, extending Metal Work’s capabilities in a way that complements its existing strengths. Similarly, the acquisition of American Cylinders addressed a practical challenge: the need to better serve a US market heavily reliant on imperial measurements. “These acquisitions aren’t about collecting trophies,” Smith emphasised. “They’re deliberate, thoughtful moves to expand our ability to serve customers in meaningful ways. AR Vacuum, for example, was already working with many of our distributors. It made perfect sense to bring that expertise under our roof. It’s about finding synergies that align with our core focus: automation and pneumatics.” This clarity of purpose has allowed Metal Work to avoid the pitfalls of expansion for expansion’s sake. “Everything we do is measured against one question: Does this improve our ability to deliver value? If it doesn’t, it doesn’t belong.” Thriving amid change: Brexit, logistics, and resilience Navigating the challenges of Brexit and the pandemic tested Metal Work Pneumatic UK’s adaptability. Importing a significant volume of Metal Work Pneumatic UK’s new Milton Keynes facility
Insight February/March 2025 www.pwemag.co.uk Plant & Works Engineering | 13 goods from Italy, the company faced logistical hurdles, including increased shipping times, customs complexities, and regulatory changes like UKCA marking. Rather than faltering, the company adapted. The Milton Keynes facility became a centralised hub for all UK operations, handling everything from imports and warehousing to bespoke solutions and distribution. The company also invested in new shipping partnerships and leveraged the robust compliance systems of its parent organisation to minimise disruptions. “This period presented significant challenges, but it also strengthened us,” Smith reflected. “The challenges forced us to refine our processes and reinforced the importance of our local facility as a pillar of our operations.” Bespoke innovation: The heart of Metal Work Pneumatic UK The company’s commitment to bespoke solutions is a defining feature that sets it apart in a competitive market. While larger competitors may prioritise off-the-shelf products, Metal Work focuses on tailoring its offerings to meet the specific needs of its customers. Smith, who spearheaded the company’s systems division during his early years, described the approach as highly collaborative. “Our goal is to establish the customers’ true requirements and then work together to create a solution that fits perfectly,” he said. A prime example is the EB 80 Valve Island, a flagship product developed in collaboration with customers. Designed to address complex operational challenges, the EB 80 integrates seamlessly into automation ecosystems while delivering precise, reliable performance. “It’s about more than just meeting needs,” Smith added. “It’s about exceeding expectations and building products that solve problems today while anticipating tomorrow’s challenges.” Agility in a competitive landscape Competing with industry giants, Metal Work Pneumatic UK has turned its comparative size into an advantage. Its agility allows the company to respond quickly to customer needs, adapt product designs, and offer services such as control panel build, sub-assemblies and custom kitting, which many of the industry leaders have moved away from in the UK. “Our size enables us to listen closely to our customers and act on their ideas,” Smith noted. “Whether it’s accommodating a special request or designing a completely new system, we pride ourselves on being a partner, not just a supplier.” This responsiveness extends beyond products. Metal Work UK provides tailored support for regulatory compliance, expedited shipments, and hands-on customer engagement, reinforcing its reputation as a trusted ally in the automation sector. Adopting technology thoughtfully As robotics and artificial intelligence (AI) reshape the automation landscape, Smith remains steadfast in his belief that pneumatics remains essential. “People like to predict the death of pneumatics in favour of electrics or robotics, but the reality is more nuanced., and Pneumatics remains an essential and important solution for industrial applications. That’s not going away anytime soon,” he asserted. While acknowledging the transformative impact of AI and robotics, Smith tempered the excitement with a dose of realism. “AI and robotics are exciting, but they can be an expensive option. For many businesses, the capital investment required to implement these systems is a significant hurdle. That said, we’re seeing gradual adoption, and it’s something we’re preparing for.” The company positions itself as both a participant in and an observer of these trends. “We’re not an AI company. We’re not designing robots. But our devices are integral to these systems. Whether it’s a robotic arm or a production line controlled by AI, our job is to ensure that our components deliver precise, reliable performance. That’s where we excel,” Smith explained. In addition to integrating seamlessly into robotic and AI-controlled systems, the company leverages AI to enhance the customer experience through predictive tools and streamlined interfaces. “Our focus is on making technical solutions more accessible,” Smith said. “Customers want simplicity and effectiveness, and AI helps us deliver that.” A culture built on collaboration and trust What truly defines Metal Work Pneumatic UK is its people-first philosophy. Smith spoke passionately about creating an environment where employees feel valued and empowered. “We’re a company of people, not just products,” he said. This ethos shapes every aspect of the business, from recruitment to retention. “When hiring, we look for attitude and initiative as much as technical skills,” Smith shared. “And we invest heavily in training to ensure our team understands not just the products but the bigger picture - how those products solve problems for our customers.” The company’s Kaizen philosophy of continuous improvement extends to its relationships with customers and employees alike. Ideas from all levels of the organisation, especially the shop floor, are welcomed and implemented to drive innovation. Leadership and legacy As Managing Director, Smith’s role is as much about leadership as it is about strategy. Reflecting on the challenges of his position, he pointed to the delicate balance between innovation and tradition. “Building a new facility or acquiring a company is exciting, but at the end of the day, it’s the people who define the business. That’s the hardest and most rewarding part of leadership—finding the right people, nurturing their talents, and ensuring they align with the company’s vision.” Smith spoke with genuine pride about the culture at Metal Work, which he described as akin to a family. “I hesitate to call us a family business because it can sound insular, but there’s a deep sense of connection here. Whether it’s the directors in Italy or the engineers on our shop floor, there’s a shared belief in what we’re doing and why it matters.” A commitment to the future As the conversation concluded, Smith reflected on Metal Work’s Ωbroader mission: balancing innovation with authenticity, growth with integrity. “Our industry is changing, no doubt about it,” he said. “But at Metal Work, we’re not chasing trends for the sake of it. We’re grounded in what we do best: delivering high-quality, reliable solutions while fostering relationships built on trust.” That trust, Smith emphasised, is the foundation of everything Metal Work stands for. “In an increasingly automated world, trust is what keeps us human. Whether it’s between colleagues, with customers, or even across borders within the company, trust is what drives innovation, collaboration, and success.” Looking ahead, Metal Work Pneumatic UK remains committed to balancing growth with integrity. The new facility and customer engagement centre mark the beginning of a new chapter in its mission to deepen connections, enhance capabilities, and push the boundaries of innovation. “Our industry is evolving, and so are we,” Smith noted. “But at our core, we remain true to what defines us: delivering high-quality solutions, fostering trust, and putting people first.” With these guiding principles, the company isn’t just adapting to a competitive and fast-moving market - it’s setting the standard for what a modern engineering company can achieve when it places trust and people at the heart of its strategy. For further information please visit: https://www.metalwork.co.uk Anthony Smith, Managing Director of Metal Work Pneumatic UK
Maintenance Matters Focus on: Condition Monitoring 14 | Plant & Works Engineering www.pwemag.co.uk February/March 2025 It is reported that when Sir John Barbirolli was once conducting the world-famous Halle orchestra in Manchester during a rehearsal, he shouted at the top of his voice…” where’s the piccolo?”. A tiny instrument that the player obviously thought would go unnoticed amongst the ensemble of large, loud instruments. A salutary lesson on how a single seemingly insignificant element can affect the entire performance. Stories like this resonate in industry too. Major manufacturing complexes often contain thousands of industrial components such as hydraulic pumps and industrial gearboxes. Some of these may seem like unimportant ancillary pieces of equipment but they are often vital to production and can bring the whole complex to a grinding halt when they fail. A good example of this is a quarry where the mined aggregate is conveyed to a ship or loading point through a series of conveyor belts. The belts themselves are driven by electric motors utilising gearboxes with each conveyor containing a multitude of roller bearings that support the belt itself as the aggregate is transported to its destination. These conveyers can sometimes cover huge distances. Take the conveyer belt system between the Mount Saddleback mine and Worsley refinery near Collie, Western Australia, the 31 km flight of the main conveyor is the longest single conveyor belt in the world. The total distance of the complete conveyor system is an incredible 51 km (31.6 miles). It is used to transport 2700 metric tonnes of bauxite ore per year, from which aluminium is produced. The roller bearings supporting the long belts may seem insignificant elements when compared to huge crushers, graders, screens and major parts of the overall process, and yet if a number of these bearings seize or fail, then the entire production can come to a halt. Potential failures of these bearings can be identified utilising thermal imaging cameras, a technique that has been successfully used for many years, saving millions in terms of lost production and catastrophic failure. However, a more recent approach is to utilise acoustic imaging cameras which can provide a much earlier warning signal when it comes to bearing failures. Acoustic imaging The latest FLIR Si2 LD acoustic imaging camera for example has different operation modes, firstly the leak detection mode (LD) that is used for detecting minute gas and air leaks in pneumatic, vacuum or speciality gas systems. Secondly, Mech Mode which can detect mechanical problems with bearings and gears way before they fail. This early warning tool is easy and quick to use meaning that even long conveyor belts with hundreds of support bearings can be analysed very quickly on a regular basis providing an in-depth health check and an early warning system, hence potentially avoiding expensive downtime. The FLIR Si2-Pro acoustic imaging camera comes loaded with a multitude of additional features. The improved performance means the new camera is capable of detecting problems at much greater distances. It shows a 70% improvement in acoustic performance compared to previous Si124 models. The camera is therefore more adapt at detecting multiple mechanical sources thanks to the improved multisource mode. The camera features a 2x and 8x digital zoom which provides images to the 5 inch colour touch screen which boasts a resolution of 1280 x 720 for both video and images with GPS, image tags and comments potentially added to images for further analysis to be conducted. Still images can be produced with both .nlz and .jpg format whilst videos can be formatted in .nlz. Data transfer can be conducted via Wi-Fi or USB with automatic over the air wireless updates ensure the camera is always up to date. Measurement data can be stored on the internal SD card up to 128GB with unlimited cloud storage available with FLIR Cloud. Weather detecting developing faults in high-voltage applications, leaks from pneumatic equipment or speciality gas installations; or mechanical issues such as bearings in conveyors, the FLIR Si2-series of cameras can provide the insights needed to maintain uptime and reduce operational expenditure. For further information please visit: https://www.flir.co.uk Early warning signs of conveyor belt bearing problems Conveyor belt roller bearings are essential for maintaining industrial operations. Their failure can lead to significant disruptions, but early detection methods, such as acoustic imaging, offer a way to identify issues before they escalate. This approach helps reduce downtime, improve efficiency, and ensure the reliability of critical systems. PWE reports.
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