NEWS | FEATURES | PRODUCTS | CASE STUDIES June/July 2025| Issue 487 www.pwemag.co.uk @PWEmagazine1 Can maglev reduce manufacturing downtime? Inside this issue: 14 > The importance of regular maintenance in minimising critical equipment failure 20 > How comprehensive assessments drive compressor reliability and efficiency 30 > What operations need to know about servicing high-voltage equipment page 12 @plant-&-works-engineering PWE Plant & Works Engineering Since 1981
VSE903: Vibration diagnostics in the field ifm.com • Fast, error-free installation and retrofitting thanks to the standard M12 connector • Robust IP 67 housing for decentralized use • Integrated separation between automation and IT networks • Compatible with all common acceleration sensors • Six signal inputs collect all relevant data to improve machine availability
While implementation will be key, the strategy provides a framework that, if delivered effectively, could help reset the trajectory of UK manufacturing. A strategic turning point for UK industry The launch of the Government’s modern industrial strategy marks a significant moment for UK manufacturing. With the publication of the white paper by the Secretary of State for Business and Trade, Jonathan Reynolds, ministers have taken a clear step towards addressing some of the long-standing structural issues that have impacted the sector’s performance and competitiveness. Make UK, which has long campaigned for a comprehensive industrial strategy, has identified three persistent challenges facing manufacturers: acute skills shortages, high energy costs, and limited access to growth finance—especially for innovative small and medium-sized Editor’s Comment ‘ ’ enterprises (SMEs). The strategy outlines plans to address all three. In particular, the Advanced Manufacturing Sector Plan sets out the ambition for the UK to become a global leader in advanced manufacturing. Through targeted support for regional manufacturing clusters, the plan aims to stimulate investment, drive exports, and equip the sector with the skills needed for the future. It signals a shift towards place-based industrial development, with the potential to deliver economic benefits across a wider range of communities. On energy, the Government’s acknowledgement of the uncompetitive costs facing UK manufacturers is notable. With industrial electricity prices often far exceeding those of international rivals, the forthcoming consultation on eligibility for lower rates will be closely watched by industry. Manufacturers will expect swift action to ensure these reforms provide meaningful relief across the sector. Skills, too, remain at the heart of industrial renewal. Government commitments to invest in engineering and tackle the skills gap are welcome, but long-term reforms to the skills and training infrastructure will be critical to match the pace of technological change and evolving business needs. Meanwhile, enhanced funding for the British Business Bank—totalling £7 billion—could improve SME access to finance, a perennial obstacle to innovation and expansion. With SMEs accounting for the vast majority of UK businesses, removing these barriers is essential to unlocking broader economic growth. While implementation will be key, the strategy provides a framework that, if delivered effectively, could help reset the trajectory of UK manufacturing. It reflects a renewed recognition within Government of the sector’s strategic value to the economy—and of the need for sustained, coordinated action to support it. June/July 2025 www.pwemag.co.uk Plant & Works Engineering | 03
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June/July 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. INSIGHT 10 MAINTENANCE MATTERS - 12 INCORPORATING PROBLEM SOLVER Focus on: Smart Maintenance/ Condition Monitoring PWE looks at the long- and short-term benefits of maglev technology for maintenance engineering. PROCESS, CONTROLS, & PLANT 20 Focus on: Compressed Air/ CHP Compressors lie at the heart of countless businesses across countless industries, and those businesses’ success depends on their equipment performing reliably, efficiently and sustainably. When this isn’t the case, they need easy and fast access to engineering excellence to assess and help them improve their compressors. 26 ENERGY & ENVIRONMENTAL MANAGEMENT 26 Focus on: Boilers, Burners & Controls/ Cooling When Sasol’s Secunda powerplant in South Africa was looking for ways to improve productivity and maintenance responsiveness, it approached Omniflex for real-time monitoring of electrostatic precipitators (ESPs) across 17 substations. PWE reports. HANDLING & SAFETY MATTERS 30 Focus on: Handling & Storage As more heavy-duty forklifts adopt high-voltage electric power, operations must understand the servicing and safety requirements. Ricky Hirani explains further. SPECIAL FOCUS FOOD & BEVERAGE 36 SEALS, BEARINGS & LUBRICATION 38 PRODUCTS & SERVICES DIRECTORY 42 Contents 10 36 20 30 BCAS official media partner
News 6 | Plant & Works Engineering www.pwemag.co.uk June/July 2025 The UK Government has published its longawaited Modern Industrial Strategy, marking what industry body Make UK has described as a landmark moment for British manufacturing. The strategy, announced by Secretary of State for Business and Trade Jonathan Reynolds, sets out a wide-ranging plan to tackle long-standing structural issues that have hampered industrial growth, including skills shortages, high energy costs, and barriers to finance for small and medium-sized enterprises (SMEs). Stephen Phipson, CEO of Make UK, welcomed the publication, calling it “one of the most important days for British industry in a generation”. “Make UK has led the campaign for a new industrial strategy for many years, highlighting the three major challenges that were diminishing our competitiveness, hampering growth and frustrating productivity gains: a skills crisis, crippling energy costs and, an inability to access capital for new British innovators,” said Phipson. He added that the Government’s response demonstrated a serious commitment not only from the Secretary of State but from the wider Cabinet. The strategy announced “sets out comprehensive and well-funded plans to address all three of these structural failings. Clearly there is much to do as we move towards implementation but, this will send a message across the Country and around the world that Britain is back in business.” As part of the broader strategy, the Government also launched its Advanced Manufacturing Sector Plan, aimed at positioning the UK as a global hub for advanced manufacturing. The plan includes support for innovation, exports, and skills development, and promotes the creation of regional clusters to help spread economic growth more evenly across the country. Lord Richard Harrington, Chair of Make UK, said: “We fully endorse the Government’s ambition to be the best place in the world to start, grow and invest in Advanced Manufacturing and welcome the Sector Plan as the first step to boosting investment in our innovative sector.” He added that the “plan sets out how Government will work with industry to help our businesses become more resilience, boost exports and upskill the people it needs for the future.” The plan includes targeted place-based initiatives designed to support manufacturing clusters and ensure more regions benefit from the jobs and economic activity that manufacturing brings. Addressing one of the sector’s most pressing concerns, the strategy includes measures to reduce industrial energy prices, bringing them more in line with international competitors. Ben Fletcher, Chief Operating Officer at Make UK, said: the Government has listened to Make UK’s concerns that industrial energy prices need to be dramatically reduced in line with international competitors: “All eyes will now be on the consultation which will set an energy intensity threshold for those companies that will be eligible for these lower rates. With over a quarter of manufacturers saying that electricity costs alone make up 11-25% of their total business costs it’s clear that the manufacturers need to be in scope. We will be pushing hard on ensuring that all of the manufacturing sector receives this support and Government moves at pace on the consultation and importantly the implementation.” On skills, the strategy pledges new investment in engineering and manufacturing training to help address the nearly 50,000 unfilled roles in the sector. Verity Davidge, Director of Policy at Make UK, welcomed the move, saying: “We know that the foundation of any successful Industrial Strategy is people. Make UK strongly welcomes the Government’s investment into engineering, and its commitment to reducing the skills gap in our sector. In supporting provision for both recruitment and upskilling, this is a promising start to filling the nearly 50,000 existing vacancies in manufacturing.” She added: “Looking ahead, it is critical that Government develops a long-term vision for skills in the sector, ensuring that all contributions made by employers can be used by employers for both the Growth and Skills Levy and the Immigration Skills Charge, and delivering the crucial funding reforms to ensure the training market is equipped and funded to train the next generation of manufacturers.” In a further move to support innovation and business growth, the strategy includes £7 billion in additional funding for the British Business Bank to improve access to capital for SMEs. Seamus Nevin, Chief Economist at Make UK, said: “”Access to external finance is one of the biggest barriers to growth for small and medium-sized enterprises (SMEs). SMEs make up 99% of the UK economy, so this longstanding challenge has significantly held back the UK economy.” Nevin added: “This announcement of new incentives, backed by an additional £7 billion in funding for the British Business Bank, marks a major step forward to support more UK businesses to invest, scale up, and seize new market opportunities — unlocking the full potential of innovative manufacturing companies to transform and grow.” Government unveils Industrial Strategy in major boost for UK manufacturing
News June/July 2025 www.pwemag.co.uk Plant & Works Engineering | 07 So the long wait is over. Make UK has long campaigned for a modern, ambitious and long-term industrial strategy which it believes is essential to achieving the Government’s mission for long-term economic growth and supporting its 5 growth missions. For too long, the UK has lacked a clear and unifying direction across its industries, leading to challenges in achieving industrial success. That is why we believe the announcement will be welcomed by manufacturers across the UK as the first step in boosting investment in capital and advanced skills. It will also show overseas investors that UK is open for business, has a stable platform and a Government committed to welcoming them here. Importantly, the strategy is cross Government and focuses on three key areas where Make UK believes urgent action was needed. First, the UKs industrial electricity prices are the highest in the developed world and presented an existential threat to companies. That is why it was vital to reduce them and the announcement of a consultation with the aim of bringing them in to line with our EU competitors is extremely welcome. It’s now essential that Government moves at pace with the consultation and implements a scheme as soon as possible so that companies can start to benefit. Secondly, an industrial strategy will only be as successful with the highly skilled workforce to take advantage of it. The sector currently faces a skills crisis with around 50,000 unfilled vacancies and the investment announced today will not just help fill these in the short term but start to develop the talent pipeline for the future. Moving forward it’s now essential Government develops a long term vision for skills for manufacturing and ensures a training system is in place to deliver it. Finally, the vast majority of manufacturers are SMEs and, for too long, access to external finance has been one of the biggest barriers to growth for small and medium-sized enterprises (SMEs). SMEs. The £7 billion in funding for the British Business Bank, marks a major step forward to support more UK businesses to invest, scale up, and seize new market opportunities. Moving forward there is still scope to do far more, especially on energy and skills. But, after so long in the wilderness, the fact that ‘industrial strategy’ is back in vogue and, at the centre of government policy is a major step forward. By MAKE UK chief executive, Stephen Phipson MAKE uk - the manufacturers’ organisation monthly news comment Global research report from Rockwell Automation reveals how UK manufacturers are leveraging artificial intelligence to enhance workforce capabilities and drive operational resilience. Rockwell Automation, the world’s largest company dedicated to industrial automation and digital transformation, has unveiled the UK findings of its 10th annual State of Smart Manufacturing Report. The research reveals that the United Kingdom is setting the pace in Europe, with manufacturers rapidly adopting artificial intelligence (AI), investing in workforce up-skilling, and prioritising cybersecurity as a strategic foundation for growth. The study, based on feedback from more than 1500 manufacturing leaders globally, highlights the UK’s striking progress in digital transformation. With 53% of UK manufacturers already implementing machine learning or AI on the factory floor, and an impressive 98% either using or planning to implement generative AI, the country is leading Europe in applied artificial intelligence. “AI is no longer just an emerging trend for UK manufacturers, it has become the driving force behind their transformation,” said Phil Hadfield, managing director at Rockwell Automation. “By combining a humancentric workforce strategy with deliberate digital investment, UK firms are not only embracing innovation but also achieving tangible performance improvements that position them as leaders in the global manufacturing landscape.” AI and generative AI are being deployed in quality control, cybersecurity, training content, and compliance reporting. Already, 15% of UK firms say GenAI delivered the highest ROI of any technology in the past year. Rather than replacing workers, UK manufacturers are using AI to enhance roles and address labour shortages. Thirty-eight percent of UK companies plan to upskill existing talent, up from 30% last year and well ahead of the European average of 30%. Cybersecurity has emerged as a foundational priority. With 97% of UK firms already investing or planning to invest in cyber platforms, and 21% citing it as their top ROI driver, businesses are building secure infrastructure before expanding digital services. Thirty-two percent now see cybersecurity as a top external risk, up from 28% last year. Meanwhile, digital twin adoption has jumped from 21% to 37% in just 12 months, with the UK reporting the highest planned adoption rate in Europe. Sustainability strategies also continue to mature, with 89% of manufacturers now operating under formal ESG policies, and 56% citing efficiency, not compliance, as the main driver. To view the full findings of the State of Smart Manufacturing Report please visit: https://bit.ly/3FQ3EdW UK emerges as Europe’s digital manufacturing frontrunner powered by AI and workforce transformation
News Three senior figures from the Institution of Mechanical Engineers (IMechE) have been awarded MBEs in the King’s Birthday Honours List, recognising their contributions to engineering and service to the profession. Past Presidents Peter Flinn and Giles Hartill, along with former Trustee Bridget Eickhoff, were honoured for their work across the industrial, defence and rail sectors, as well as their longstanding support for engineering through IMechE. IMechE President Matt Garside said: “We are incredibly proud that the King has honoured Peter, Giles and Bridget. Their drive and commitment reflect the very best of our profession.” Flinn, President in 2021, helped establish the Manufacturing Technology Centre and held key roles at the High Value Manufacturing Catapult and Aerospace Technology Institute, promoting UK industrial innovation. Hartill, President in 2023 and now Chief Technologist at AWE Nuclear Security Technologies, has led major R&D programmes in the defence sector and championed engineering education. Eickhoff, Principal Infrastructure Engineer at the Rail Safety and Standards Board, has had a distinguished career in rail and remains active in mentoring young engineers through IMechE’s Railway Challenge. Eickhoff said she was “delighted” by the honour and credited colleagues for their support. Hartill called the award “deeply humbling” and thanked those who had supported his journey. Flinn said the recognition “made it all worthwhile” after more than 50 years in engineering. MBEs are awarded for significant contributions to public life and service in the UK. Three IMechE members awarded MBEs in King’s Honours Fluid Filtration launches in the UK May 2025 saw the launch of Fluid Filtration which will exclusively sell Ikron filters in the UK. The company was founded by industry veteran Sophie Fisher, who said it will reflect her commitment to integrity, quality, and customer service. After a distinguished 35-year career with a single organisation, redundancy in March 2024 prompted Sophie Fisher to reassess her professional direction and reconnect with her passion for the fluid power sector. Over the past year, she recognised that re-entering the industry required a fresh approach: “It’s about more than just business; it’s about integrity, accountability, and a commitment to quality and customer service,” she explained. “Working with partners who share those principles is essential.” Her search led to a partnership with Ikron Srl, an Italian manufacturer of hydraulic filters and a subsidiary of the Casappa Group — a global leader in pumps, motors, filters, and hydraulic systems based in Parma, Italy. To mark its launch, Fluid Filtration is offering free delivery for the first 20 customers placing orders for delivery by December 2025.
News The winners of The Big Bang UK Young Scientists & Engineers Competition 2025 have been announced, recognising the creativity and ingenuity of young people across science, technology and engineering. Top honours — UK Young Engineer and UK Young Technologist of the Year — were awarded at the Big Bang Fair, hosted by EngineeringUK. Aaron Lord, a Year 12 student from Greenhead College, Yorkshire, was named UK Young Engineer of the Year for his project Autopill — an automatic pill dispenser designed to support people with dementia or memory difficulties. The device includes reminders and health monitoring features, combining mechanics, electronics, and CAD. Engineering category winners also included: Junior Engineering: Gayatri Thiru (Invicta Grammar School, Kent) for a solar-powered nanotech device to clean oil spills. Intermediate Engineering: Om Kuravinakop (St Olave’s and St Saviour’s Grammar School, London) for a handheld air quality monitor for asthma sufferers. Senior Engineering: Grace Palmer (WMG Academy, Solihull) for Thrive Transfer Aid, a device to support the safe movement of disabled children. Muhammad Shah, a Year 13 student from Queen Elizabeth’s School, Barnet, won UK Young Technologist of the Year for Icarus, a decentralised emergency communications system for use in remote areas. Supported by Siemens, the award recognises innovation in digital and sustainable technology. Muhammad, currently sitting A levels, will receive his award at a later school event. Alice Morrish (Invicta Grammar School, Kent) was named UK Young Scientist of the Year for Quantum Karate, while other standout projects included an AI tool for cancer diagnosis, a menopause cooling stick, and a pollution-converting facemask. Dr Hilary Leevers, Chief Executive of EngineeringUK, praised the winners: “They’ve shown remarkable knowledge, creativity and determination. The future of STEM is in very capable hands.” For the full list of winners, visit: www.thebigbang.org.uk/competitionwinners Young innovators shine at The Big Bang UK competition 2025 Aaron Lord, from Greenhead College in Yorkshire, was awarded UK Young Engineer of the Year for his project ‘Autopill’
10 | Plant & Works Engineering www.pwemag.co.uk June/July 2025 Insight More than just a showcase of products and services, the event was defined by its ambition to push the boundaries of what a manufacturing exhibition can deliver. With a focus on rich technical content, forward-looking innovation, and the sector’s most pressing priorities, Smart Manufacturing Week offered a comprehensive platform for learning, collaboration and inspiration. Welcoming 13,319 attendees across two days, the event combined impressive technology with an extensive educational programme and a vibrant show floor. Adding extra flair were celebrity look-a-likes, movie Smart Manufacturing Week 2025 showcases innovation, collaboration and industry impact Smart Manufacturing Week 2025 returned to the NEC Birmingham on 4–5 June. Bringing together Smart Factory Expo, Design & Engineering Expo, Drives & Controls, and Maintec— alongside specialist zones for Fluid Power & Systems and Air-Tech—the event offered wide-ranging insight into the technologies and trends shaping modern industry. PWE reports. robots, and live music, creating a dynamic atmosphere that celebrated innovation and industry. With 456 exhibitors on the show floor, attendees explored hundreds of cutting-edge products and innovative solutions driving the future of industry. Solutions Theatres Alongside the exhibition floor, the Solutions Theatres delivered over 170 free-to-attend educational sessions led by experts in manufacturing and technology. Covering key themes such as Industrial Data & AI, IIoT & Connectivity, Digital Transformation and Leadership and Strategy, the programme offered valuable insights for professionals at every level. Attendees also benefited from practical workshops hosted by the Institute for Manufacturing and explored the latest advancements showcased in the ever-popular Innovation Alley. A brand-new feature for 2025, Smart Tank took place on Day 1. Exhibitors from Innovation Alley pitched their business ideas and solutions to a panel of industry leaders, who scored entries based on criteria ranging from innovation to market size to business readiness. Two sessions ran, with a winner crowned from each. Uie impressed the judges with the simple
Insight June/July 2025 www.pwemag.co.uk Plant & Works Engineering | 11 ingenuity of its batteryless heat sensor for electrical condition monitoring applications, while Logidot, stood out for taking the idea of GPS vehicle tracking software, moving it inside the factory and then expanding its capability to create a unified seamless system. Both winners received a prize package designed to accelerate their growth, including complimentary exhibitor space at next year’s event, access to a mentor, investor introductions, media coverage and free advertising. In the Solutions Theatres a standout moment on Day 1 came from Professor Henrik von Scheel, whose headline keynote The Future of Manufacturing: Megatrends Shaping the Next Decade drew significant attention while Former Team Principal of the Haas Formula 1 Team, Guenther Steiner captivated visitors on Day 2 with a keynote that offered rare insight into the high-stakes world of elite motorsport. Manufacturing Digitalisation Summit Alongside this, the Manufacturing Digitalisation Summit brought together senior leaders from across the sector to explore how AI and digital technologies are shaping the future of industry. With real world insights from global manufacturers, the summit delivered practical knowledge and high-impact exchanges between decision makers from multiple sectors. Providing an extensive STEM programme, Smart Manufacturing Week’s Manufacturers & Engineers of the Future extended its reach to welcome school-age students for the first time, alongside apprentices and those already pursuing further education. Sponsored by FANUC, the initiative offered a dynamic mix of hands-on workshops, live demonstrations and speaker sessions designed to expose young people to the possibilities within manufacturing and engineering. Highlights included the WorldSkills UK Industrial Robotics Competition, Coventry University’s Hydrogen Power Workshop and career-focused contributions from organisations such as Lisi Aerospace. Attendees also met current apprentices, gained insight into real career pathways and saw emerging talent in action, helping to spark genuine interest in the sector’s future. The festival atmosphere was genuine with music upon entry, Elton John, Dolly Parton, Stormzy, Lady Ga-Ga and Ed Sheeran look-alikes walking the floor and a piano busking spot. The Guitar Legends Competition, a muchloved feature of Smart Manufacturing Week, gave engineering guitarists a chance to showcase their musical talents. A winner was crowned on each day of the event, with both taking home a custom 3D-printed guitar. Day 1’s winner also joined live band The Shadow Monkeys on stage, adding to the energy and entertainment of the evening drinks reception. Event Director, Grace Gilling said :”It’s been incredible to feel the buzz throughout Smart Manufacturing Week 2025. We knew this year would be special, but the response has truly exceeded expectations. From the moment doors opened to the final moments, the floor was alive with innovation, collaboration and a real sense of excitement for the future of manufacturing.” Reflecting on the wider impact of the event, Chloe Bale of Make UK commented: “Events like this remind us just how much potential our sector holds when we come together to share ideas, solutions, and ambition.” The dates for the Smart Manufacturing Week exhibitions next year have been confirmed as 3-4 June 2026. For more information visit: https://bit.ly/4kzvXfK
Maintenance Matters Focus on: Smart Maintenance 12 | Plant & Works Engineering www.pwemag.co.uk June/July 2025 Can maglev reduce manufacturing downtime? What really grinds manufacturers’ gears? Costly downtime and worn-out machinery. Maglev technology takes friction out of the equation, reducing the need for both scheduled and unscheduled maintenance activity. PWE looks at the long- and short-term benefits of maglev technology for maintenance engineering. Traditional manufacturing systems rely on mechanical bearings and rollers, which suffer from friction-induced damage over time. This ongoing degradation leads to breakdowns, frequent maintenance and costly replacements. Magnetic levitation (maglev) technology addresses these issues by using electromagnetic fields to suspend and transport objects without physical contact. By eliminating friction, maglev significantly reduces wear and tear on machinery. This results in longer lasting equipment operating with greater precision, while reducing maintenance requirements. In industries like steel production and aerospace manufacturing, where moving heavy components can compound this problem, this technology has proven to be a very valuable tool. Maglev in smart factories The rise of Industry 4.0 has led to the widespread adoption of IoT, AI and automation in smart factories. Maglev technology is becoming an integral part of this transition, offering seamless integration with softwaredriven manufacturing processes. One very important aspect of smart factories is an uninterrupted uptime. By minimising maintenance and cleaning needs, maglev systems ensure production runs smoothly. It also complements PC-based control solutions and IoT-based monitoring systems well, where predictive analytics can help prevent hardware failures before they occur.
Focus on: Smart Maintenance Maintenance Matters June/July 2025 www.pwemag.co.uk Plant & Works Engineering | 13 The combination of smart software and frictionless hardware is particularly valuable in highly regulated industries. In semiconductor manufacturing and pharmaceutical production, contamination control is critical. Traditional mechanical transport systems can introduce microscopic particles that would compromise the products — a problem that maglev-based conveyors navigate without difficulty. Energy efficiency & sustainability Efficiency in manufacturing extends beyond production speed but also encompasses resource usage and environmental impact. In addition to lower maintenance requirements, maglev technology is inherently energy efficient. The lack of friction means that less power is required to maintain movement, leading to reduced operational costs and carbon footprint. Maglev systems also have no need for lubricants and frequent part replacements, minimising waste material throughout its machining lifespan. Motion Traditional conveyor systems usually require multiple machines to accommodate directional changes and varying speeds. In contrast, maglev-based transport solutions enable controllable, omnidirectional movement with a single unit, streamlining robotic assembly lines and other automated processes. It is in the optimised production layouts, where maglev transport systems rises to another level. The motion surface comprises of modular tiles that can be arranged freely depending on current requirements. This also means that installing transport pathways to meet new demands is simple. Mark Richards, UK Sales Manager at Beckhoff Automation UK, points to the company’s maglev transport system, Xplanar, as a solution. Xplanar tiles feature independently powered position detection, allowing the system to resume operation precisely where it left off after maintenance or tool changes. Personalised manufacturing has become increasingly important in many industries, which requires flexible manufacturing set-ups. Richards says that the simultaneous operation of different mover sizes on an XPlanar system eliminates the need to modify transport systems, which can lead to delays especially when processing a large variety of products and packaging sizes. Maglev technology was once a futuristic concept but is now a practical solution that enhances efficiency and minimises downtime. This increased system availability is largely thanks to the sophistication of automation software. All functionalities are integrated into one PC-based control system, like TwinCAT, which streamlines user-machine interactions. As manufacturers prioritise efficiency, precision and sustainability, maglev technology is emerging as a transformative solution. Reducing downtime is becoming increasingly important, making flexible, frictionless transport a significant step forward in manufacturing innovation. For further information please visit: www.beckhoff.com/ TECHNICAL TRAINING SOLUTIONS Providing Practical Electrical, Instrumentation & Mechanical Skills Training for Industry since 1980 LEARNING BY DOING technicaltrainingsolutions.co.uk tech.training@zen.co.uk 01634 731 470 PWE 1.4 PAGE MASTER 2025.indd 1 10/02/2025 12:53:21
Maintenance Matters Focus on: Condition Monitoring 14 | Plant & Works Engineering www.pwemag.co.uk June/July 2025 Could your business withstand losses of £2M per hour? This eyewatering figure comes from research into the true cost of manufacturing downtime by IDS-INDATA. It is suggested as potentially the average cost of a single production downtime incident for UK automotive manufacturers in 2025. Furthermore, the researchers suggest that, across the automotive manufacturing sector, there could be as many as 20-25 downtime episodes a month, each lasting around 3-4 hours. Automotive manufacturing isn’t the only industry likely to suffer production outages. Based on the data analysis, food processing plants could have multiple minor stoppages every week, adding up to around 442 hours of downtime over the year and costing companies up to £25,000 each time. In the last three years, the report advises that more than 80% of industrial businesses in the UK and Europe experienced unplanned downtime. Each incident lasted around four hours. Any production downtime won’t just impact on the bottom line; there are the associated costs that companies will incur as a result, including emergency engineers’ call-out, repairs, spare parts, and possibly even overtime to get the line up and running again. Plus, of course, there are intangible costs, including the reputational damage that a company will inevitably suffer if it fails to fulfil customer orders. Software and systems failures are cited as one of the leading causes of production downtime, which is no surprise; factories can be hostile places for IT circuits. Dust is a constant irritant that can never be fully removed. Even the ‘cleanest’ industrial spaces will have a base level of particles within the air that will be drawn into equipment enclosures if cooling fans are employed. This dust can get into both wire connections and internal component fans, either blocking and shorting wiring connections or preventing thermal exchange. Even where an environment is kept hygienically clean, such as in the food and beverage industry, raw ingredients (including sugars and yeast) can still enter enclosures and damage the expensive machinery contained inside. Electrical equipment is also very sensitive to temperature fluctuations, typically working best within closely defined parameters. Maintaining a stable temperature is vital to ensure that all the electrical components work to their full potential and that the production equipment they control can operate at high speed. The faster a palletwrapping machine works, for example, the more goods can be shipped. Unfortunately, not only do electrical circuits generate considerable levels of (waste) heat, the impact of this heat can be exacerbated by the ambient heat of its local environment. Without adequate cooling, temperatures within an enclosure can quickly exceed the maximum levels required by the equipment. Each of these factors, whether solus or combined, represents a major risk to facilities that are under pressure to keep their production lines moving to avoid some of the financial losses we’ve highlighted. Why invest in regular electrical maintenance? The only way to manage optimum performance and ensure the longevity of your electrical systems is through a regular programme of professional service and maintenance. Some of the benefits of regular maintenance include: Improved Efficiency: it keeps systems running at peak performance, enhancing productivity The importance of regular maintenance in minimising critical equipment failure UK manufacturers are facing significant costs from unplanned equipment failures, with incidents in the automotive sector potentially reaching £2 million per hour, according to IDS-INDATA. Regular maintenance and strategic planning are crucial for minimising disruptions, maintaining efficiency, and controlling costs across various industries, including food processing and heavy machinery. PWE reports.
Seals, Bearings, & Lubrication Process, Controls & Plant smooth operation, optimises performance, and minimises downtime, ultimately enhancing productivity and reliability in the manufacturing process. Applications for smart bearings The advantages of smart bearings with builtin sensors have seen them gain popularity by being widely used in automotive anti-lock braking systems (ABS) for years. In early systems, the sensors were mounted near the tires, exposing them to contamination such as water, dirt, and grit. However, modern systems have integrated the sensor into the bearing housing which protects it from the elements. For example, SKF manufactures groove ball bearings with integrated sensors that are capable of measuring various factors such as speed, acceleration, number of revolutions, and direction of rotation. These bearings are utilised in applications including electric motors, gearboxes, linear actuators, and shafts, where precise control and monitoring are essential. The bearings can be integrated with a second sensor to determine the direction of rotation, allowing for comprehensive monitoring of machinery movements. Furthermore, the bearings are designed to withstand a wide temperature range (minus 40 to plus 120 degrees Celsius), making them suitable for industrial environments. This data aligns with the scenario described, showcasing the practical application of smart bearings in an automated manufacturing facility for continuous supervision and optimised equipment operation. Smart bearings with built-in technology also have potential uses in motors, pumps, and fans, which are essential parts of many machines. For example, if dirt contaminates a fan's blades, it causes vibration. Detecting these vibrations early can help adjust the system quickly, reducing the risk of equipment failure and costly repairs. In industries like mining, if a fan supplying fresh air breaks down and air quality suffers, all work stops immediately. Furthermore, smart bearings can be part of the "data transmission, storage, and analysis technologies" outlined in the EC’s report. Bearings with integrated sensors can send signals to an external monitoring unit. This unit records performance data and predicts how much longer the component will last. Operators can then receive alerts in real-time wirelessly, removing the need to be on the shop floor constantly as information can be accessed remotely. Going forward, and in tandem with the increased used of IIoT sensors and evolving technologies like generative AI, industrial bearings will remain essential to the effective performance of plant machinery. As the EC’s vision for Industry 5.0 takes shape, integrating sustainability, human-centric values, and resilience into industrial practices, sensor-equipped smart bearings will emerge as a pivotal technology. For further information please visit http://www.smbbearings.com @PWEma 9 on Follow gazine1 us Plant & W on Link w Follo Plant & W Facebo Join us F c Works Engineering kedIn us k Works Engineering ok on Engineering orks Plant & W E www.pwe the PWE Forthe t PW emag.co.uk website t news visit lates WEw g g One show, a thousand solutions 9000+ attendees 27 years as the South’s leading industry show 600+ exhibitors Agnieszka Radecka Regional sales manager, TME “ This has been absolutely fantastic—far beyond our expectations! The turnout has been incredible, with more visitors than we ever anticipated. We’ve attended other shows across Europe in recent months, and this one is by far the largest. The energy has been amazing right from day one, with a constant flow of enthusiastic visitors. We’re thrilled with the outcome! southern@easyfairs.com | +44 (0)20 3196 4414 Scan to register for free Register today using code 1020 01706 835331 info@spminstrument.co.uk www.spminstrument.co.uk
16 | Plant & Works Engineering www.pwemag.co.uk June/July 2025 Maintenance Matters Focus on: Condition Monitoring and reducing energy consumption Avoiding Downtime: it identifies issues and ‘hidden’ wear and tear issues early, helping to prevent unexpected system failures, and ensuring continuous production line operations. For ex?ample, removing dust and dirt around the cooling unit heat exchanger Cost Savings: it reduces the risk of more expensive repairs by identifying and addressing issues before you get to the point of critical systems failure. For example, major electrical failure due to overheated componentry Value Retention: it maintains the value of your system by addressing wear and tear proactively Overall, regular professional maintenance supports safe, efficient, and cost-effective system operation. ?However, the current labour shortages and skill gaps in manufacturing will inevitably impact on in-house response times for maintenance and repairs, particularly when you consider that August is one of the peak periods for planned maintenance in the automotive and heavy machinery sectors. That means it’s almost certain that maintenance checks will coincide with workforce holidays and other production requirements such as retooling, which can only increase the pressures on the company’s service engineering teams. Service strategies Effective service strategies are crucial in managing the risks associated with equipment failure. Rittal’s “360° Service” programme, for example, is designed to support businesses by providing comprehensive maintenance solutions. This includes specialist service engineers who act as an extension of in-house teams, enabling them to focus on core tasks while maintenance and diagnostics are handled professionally and efficiently. Competitive pricing and regular pricechecking are part of Rittal’s service commitment, ensuring accessibility and cost-effectiveness. With a focus on reliability and tailored solutions, programmes like these aim to minimise downtime and maintain operational stability. Looking ahead No business wants to be faced with high unexpected costs caused by equipment failure. Sadly, industrial environments are hostile spaces for electrical equipment; their components don’t react well to high levels of moisture, dust, and heat in the atmosphere. This sensitivity will affect plant efficiency and will ultimately lower output and profitability. To mitigate the risks associated with equipment failure, manufacturers should prioritise maintenance and service strategies that enhance reliability and minimise downtime. Investing in preventive measures can help reduce the incidence of unexpected breakdowns, safeguard productivity, and protect revenue streams. By adopting a proactive approach, UK manufacturers can better shield themselves from the disruptive impact of critical equipment failures, maintaining operational stability and supporting long-term competitiveness. For more information on “The Real Cost of Downtime in Manufacturing: Sector-bySector Breakdown and 2025 Forecasting,” go to: https://idsindata.co.uk/manufacturingdowntime-costs-and-forecasting/ Rittal’s “360° Service” programme: 1. Assembly, Installation, and Commissioning: our engineers will set-up your infrastructure, as well as provide detailed commissioning logs and operator training 2. Transparent System Efficiency Checks: no-one wants to pay more than they must for energy. As part of a regular maintenance schedule, we run comprehensive analyses across all the operating data from your units using our proprietary diagnostic software. We share the results with you and offer advice based on energy savings analyses 3. Professional Maintenance and Inspections: we will ensure you are able to maintain optimum system uptime (as well as value retention) 4. Fast Diagnostics Through Digital Tools: our Scan & Service App uses QR codes to give you quick and easy spare parts management, initial diagnostics, and service notifications. 5. Technical Support & Troubleshooting: we provide 24/7 nationwide support 365 days/year, with fast response times (aligned with service agreements) from certified Rittal service technicians and partners 6. Fast Efficient Repairs: we know our products better than anyone! Our technicians are trained in Germany to deliver fast, effective and professional repairs using Rittal original spare parts, to ensure operational safety and productivity 7. Tailored Service Agreements: we provide tailored, customised agreements covering maintenance, warranty extensions, and the stocking of spare parts, in order to minimise your downtime and reduce unexpected cost 8. Original Spare Parts: perhaps not surprisingly, we have high constant stock availability of manufacturer-certified spare parts customised to the individual unit and with 100% accuracy of fit and reliability thanks to global Rittal standards 9. Equipment Upgrades & Modernisation: where appropriate, we offer recommendations on modernising equipment to help minimise your costs through improved efficiency and reduced energy consumption 10. Reduced Risk of Repair Costs: companies who are signed up to a regular programme of maintenance benefit from a warranty extension of up to 5 years For further information please visit: www.rittal.co.uk
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