NEWS | FEATURES | PRODUCTS | CASE STUDIES www.pwemag.co.uk @PWEmagazine1 OEE and the circular economy Inside this issue: 26 > Breaking down MCPD compliance 34 > Preparing the workforce for the realities of Maintenance 4.0 38 > PPMA 2025 Preview page 14 @plant-&-works-engineering PWE Plant & Works Engineering Since 1981 August/September 2025 | Issue 488
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Predictive and proactive maintenance, powered by AI, is enabling better scheduling, extending the life of assets, and improving efficiency. Technology and skills drive smarter maintenance Artificial intelligence is now a routine part of operations in many plants and facilities across the UK. Predictive and proactive maintenance, powered by AI, is enabling better scheduling, extending the life of assets, and improving efficiency. Rather than replacing skilled teams, these systems are supporting them - taking on complex diagnostics and data analysis so that engineers can focus on higher-level decision-making and planning. Digital twins have also moved beyond early trials to become practical tools used in day-to-day operations. Their ability to create accurate, data-rich models of Editor’s Comment ‘ ’ equipment and processes is helping organisations forecast more accurately, manage assets remotely, and carry out maintenance with greater precision. The latest generation of twins, enhanced by AI, is providing deeper insight and integration across the entire lifecycle of assets, supporting more reliable and sustainable operations. These developments are starting to work together in meaningful ways. Companies are using AI and digital twins not only to improve productivity but also to meet energy and emissions targets. Efficiency gains, reduced downtime, and better resource planning are becoming essential as businesses adapt to rising costs and stricter environmental expectations. At the same time, investment in skills is helping teams adapt to these changes and make the most of the technologies being introduced. Encouragingly, the next generation of engineers appears ready to build on this progress. This year’s A-level results showed a steady rise in STEM subjects, with maths, physics, and engineering seeing particular growth. University acceptances for engineering and technology courses are also up, indicating a growing pipeline of skilled talent entering the sector. This momentum is vital as industries seek to close skills gaps and ensure that digital transformation is sustainable in the long term. The pace of change is steady and unlikely to slow. For UK industry, the challenge in the months ahead will be ensuring these technologies are accessible to organisations of all sizes,not just those with significant resources. Digitalisation, combined with practical application and a welltrained workforce, is no longer optional. It has become a core part of how maintenance and manufacturing operate today, and it will continue to shape the sector as we move into the final quarter of 2025 and beyond. August/September 2025 www.pwemag.co.uk Plant & Works Engineering | 03
Make sure you join the celebration... In this landmark 80th Anniversary year, the AEMT Awards will once again shine a spotlight on the people, companies, and innovations driving progress in the electro-mechanical sector. The awards recognise and reward the products, projects and services that play a crucial role in ensuring our food production, utilities, manufacturing processes, transportation and other essential services are maintained and secured. So whether you have submitted an entry or not, this is an industry event not to be missed. Produced by and operated by The Association of Electrical & Mechanical Trades 2025 Partners: AWARDS Book Seats at: www.aemtawards.com
August/September 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: CMMS/ OEE As UK engineering operations modernise, CMMS platforms are expected to integrate seamlessly with IoT, enterprise and analytics systems. PWE reports. . PROCESS, CONTROLS, & PLANT 20 Focus on: Compressed Air/ Seals, Bearings & Lubrication As energy costs and carbon pressures rise, compressed air systems are gaining attention. PWE spoke to Richard Hewitt, Managing Director, Anglian Compressors, who explains how businesses can cut waste, save money, and rethink this often-overlooked utility. ENERGY & ENVIRONMENTAL MANAGEMENT 26 Focus on: Boilers, Burners & Controls/ HVAC PWE looks at demystifying the technical aspects of MCPD compliance and how burner technologies can make it easier to meet regulatory requirements. HANDLING & SAFETY MATTERS 30 Focus on: Health & Safety The BSIF Height Safety Special Interest Group (BSIF HSG) offers an overview of the new Personal Fall Protection Equipment Standard, BS 8681, and outlines its implications for the industry and those it impacts. SPECIAL FOCUS NET ZERO 32 SKILLS & TRAINING 34 PPMA PREVIEW 38 PRODUCTS & SERVICES DIRECTORY 42 Contents 10 32 20 30 BCAS official media partner
News 6 | Plant & Works Engineering www.pwemag.co.uk August/September 2025 Emerging technologies such as artificial intelligence (AI), machine learning (ML), and digital twins are rapidly transforming enterprise asset management (EAM), according to the latest Maintenance Trend Report from Ultimo. Yet despite this technological shift, the research underlines that effective maintenance remains fundamentally a human-led activity. The global survey of more than 200 maintenance professionals shows a sharp rise in interest in advanced technologies compared with the 2023 edition of the report. When asked which innovations would have the greatest positive impact on maintenance and business practices, 68% of respondents pointed to contextual intelligence — up from just 8% last year — followed by automation and robotics (49%) and machine learning (41%). Interest in digital twins has also more than doubled, now reaching 40%. However, alongside enthusiasm for new tools, organisations continue to face pressing workforce challenges. Nearly two-thirds (63%) of respondents cited an ageing workforce as the most significant factor shaping maintenance strategy, emphasising the need for knowledge transfer and workforce planning. Recruiting skilled staff also remains a concern, with 50% saying it had been the primary source of operational disruption in the past year. “From global instability to changing regulations, socio-economic and political shifts are creating uncertainty across industries. In this environment, agility is critical,” said Berend Booms, Head of EAM Insights at Ultimo, an IFS company. “EAM can also serve as a catalyst for innovation. Internet of Things (IoT), AI, ML, digital twins, and predictive analytics are rapidly transforming industrial businesses. They unlock smarter decision-making, greater efficiency, and a sharper competitive edge.” The report highlights how real-time data insights from IoT devices and predictive modelling — whose perceived value has tripled since 2023 — are helping organisations unlock new opportunities in maintenance planning. Yet, almost half (49%) of respondents identified a lack of in-house expertise as a barrier to adopting these advanced tools. The findings also emphasise that while AIenabled platforms are reshaping maintenance practices, people remain central to driving success. Modern EAM systems have evolved from static data repositories into predictive tools, helping teams shift from reactive maintenance towards proactive strategies. By combining AI with operational data, these systems can identify recurring failures, optimise workflows, and minimise downtime, effectively becoming a strategic adviser to asset managers. As the report concludes, the future of maintenance will depend on a balance of human expertise and digital intelligence. Produced in collaboration with Verdantix, TwinThread, ABS Consulting, and MaxGrip, the report is available for download at: www.ultimo.com/report Report finds emerging technologies are reshaping asset management, but people remain key Remote monitoring specialist Omniflex is celebrating its 60th anniversary, having been founded as Control Logic (Conlog for short) by John Moshal and Alan Murray in 1965 in Durban, South Africa. The duo were inspired by the potential of the newly-invented transistor. Throughout its history, the company has delivered technologically innovative solutions for key industries, including mining, nuclear, petrochemical, and oil and gas, for notable clients like Sasol, Sellafield, New South Wales Ports and Port of Melbourne. In 1965, Moshal and Murray founded Conlog leading the way in replacing bulky wiring intensive, power-hungry mechanical relays with small, elegant, electronic modules. Their secret weapon was an octalbased transistor logic module that slashed complexity and boosted maintenance performance in industrial systems. This is what caught the eye of renowned Anglo American chairman Harry Oppenheimer in the early 1970s and inspired him to provide the funding that kickstarted the company’s growth in South Africa. “Since its inception, Omniflex has been about listening, designing, tweaking and delivering exactly our customers need, even when it means pushing the boundaries of technological capabilities or going against the industry consensus,” explained David Celine, managing director of Omniflex. Flexibility and reliability became Conlog’s core principles and remain an integral part of Omniflex’s culture today. This saw the company earn the respect of engineers across key industry sectors and helped to establish the firm as the leading experts for complex, high-stakes industrial automation. The company is sharing its highlights from each decade of its history in a series of blogs on its LinkedIn account. Omniflex celebrates 60th anniversary
News August/September 2025 www.pwemag.co.uk Plant & Works Engineering | 07 A new report, Making it Smarter: Global lessons for Accelerating Automation and Digital Adoption in UK Manufacturing, launched by Make UK and Sage reveals that nearly half of British manufacturers identify a lack of technical skills as the biggest hurdle to improving their use of innovative advanced technologies. Those projects which do start often stall after implementation stage, because companies cannot find the help and advice they need to make the technologies work well. Countries where all SME innovation funding and advice is held under one easy-toaccess ‘umbrella hub’ have dramatically higher success rates. The Government’s recent Industrial Strategy sets out how it will create a digitally literate workforce by 2035, but we simply can’t wait ten years for this to happen. Make UK is calling on Government to embed targeted funding for digital skills needed in manufacturing and engineering to accompany the existing £100m already set aside for engineering skills. For decades, South Korea has been undergoing a successful automation drive to transition from legacy production methods to advanced digitalised factories. It has stuck religiously to a single strategy, concentrating on education, infrastructure and innovation. The Government provides SMEs with bespoke incentives – offering easy to access R&D tax incentives of 30% for companies investing in semiconductor facilities, and broader tax credits guaranteed to 2029 and beyond. The South Korean Government also saw the need to make education work for industry – providing the employees to power the technologies. It committed to training 40,000 people to operate fully automated production systems and there are now no skills shortages in technical and digital innovation. The rewards are high; firms adopting smart technologies see a 25% increase in productivity and a 27% drop in defects. Singapore underwent a similar transformation, now a global leader in high-value advanced manufacturing, concentrating on the lucrative semiconductor market, precision engineering, pharmaceuticals and clean energy. Singapore’s pro-innovation environment delivers some of the most generous R&D tax incentives in the world, where companies can claim up to 400% tax deductions on local R&D or opt for a 20% cash payout. The incentives are embedded in a long-term industrial policy, giving SMEs and start-ups greater cashflow certainty and the ability to grow to their full potential. With a population no larger than London’s, Switzerland delivers a manufacturing output of around £150 billion — astonishingly close to the UK’s £217 billion. This remarkable productivity stems from a national strategy that prioritises advanced technologies, SME competitiveness, and long-term innovation. By MAKE UK chief executive, Stephen Phipson MAKE uk - the manufacturers’ organisation monthly news comment Aggreko has strengthened its industrial HVAC and process temperature specialist support with the appointment of Chris Smith as Head of Temperature Control for the UK and Ireland. Bringing over 22 years of experience at Aggreko across Europe, Chris is set to lead Aggreko’s support for industrial HVAC contractors, engineers and facilities management companies across sectors, including manufacturing, data centres and construction. This includes providing temporary and supplementary cooling, heating and dehumidification solutions to assist on sites during maintenance works, system upgrades, temperature spikes and in emergency outages. The appointment comes as companies across the UK and Ireland continue to experience operational and process temperature challenges caused by changing weather patterns throughout the year. With the high temperatures spikes experienced over the summer, there is increasing strain on HVAC systems across industries, resulting in further demand on contractors to provide reliable and efficient temporary solutions while balancing vital maintenance and upgrade schedules. Responding to this, Aggreko has strengthened its capacity to support contractors and facilities management companies – both in fleet and developing the expertise in order that solutions are correctly specified – to ensure that sites have the resilience need. Speaking on his appointment, Chris said: “It’s great to lead our expert teams in supporting industrial HVAC professionals and facilities managers across the UK and Ireland with their temperature control needs. With unrivalled experience in the power sector, Aggreko is best placed to ensure that our solutions are powered to operate as efficiently and sustainably as possible. Our experience in across Europe, where extreme temperatures and changing weather patterns are more common, we are accustomed to help our customers handle any challenges that may present themselves across the year. “We are able to also achieve better optimisation and efficiency to deliver both cost and environmental savings through data collected through our control and monitoring solution, Aggreko Connect. “I’m ready to hit the ground running and help our customers futureproof their industrial HYVAC and process temperature control solutions so that it can combat any weather throughout the year.” Aggreko strengthens UK & Ireland HVAC support with new head of temperature control Chris Smith, Aggreko Head of Temperature Control for UK and Ireland
News 08 | Plant & Works Engineering www.pwemag.co.uk August/September 2025 Engineering and technology courses have seen the largest increase in placed applicants in this year’s university admissions, according to new data released on A Level and T Level results day. The figures also show that, for the second year in a row, STEM subjects have grown in popularity, with mathematics remaining the most popular A Level subject. While demand for engineering at university and college is rising, research from Universities UK has highlighted a reduction in funding allocation for so-called “high-cost” courses such as engineering. This trend is seen as a concern, given that the Government’s Industrial Strategy identifies engineering skills as “at the heart” of several priority growth sectors. The Institution of Mechanical Engineers is continuing to urge the government to support the university sector in addressing the gap between demand and funding for high-cost courses. This year also marks the second cohort of students completing the Engineering and Manufacturing T Level. Sector bodies say they are closely monitoring the destinations of these learners. Alongside T Levels, BTEC and other vocational qualifications remain important routes into engineering careers, providing pathways to apprenticeships and technical roles. Employers and sector organisations, including members of Skills England, have committed to working together to ensure regional opportunities are available for young people entering the engineering workforce. Surge in demand for engineering courses UN plastic pollution talks collapse amid global divisions Global negotiations aimed at tackling plastic pollution have collapsed, with nations deeply divided over how best to address the escalating crisis. According to the BBC, this was the sixth round of talks in under three years. More than 100 countries have been pushing for a reduction in plastic production, while oil-producing states argue for a greater focus on recycling initiatives. While plastics underpin almost every modern industry, scientists are increasingly sounding the alarm over toxic chemicals leaching into soil, waterways, and even human bodies in trace amounts. In the UK, the government introduced new restrictions in October 2023 on the sale of certain single-use plastics. Retailers, takeaway outlets, and hospitality venues are now banned from supplying plastic cutlery, balloon sticks, polystyrene cups, and food containers. The move targets products that contribute disproportionately to plastic waste, with research showing that only 10% of the 2.7 billion single-use cutlery items used annually are recycled. The decision was welcomed by igus, a global leader in motion plastics, which called the legislation “a positive step toward reducing environmental harm and accelerating the transition to a circular economy”. The company continues to support efforts to combat single-use plastics as the UN process remains deadlocked. However, igus argues that genuine, long-term change requires more than bans alone. Through its chainge recycling programme, the company enables customers to return used plastic energy chains for responsible recycling and reuse—an approach it says actively promotes a circular economy by keeping valuable materials in use and out of the waste stream. The company is also innovating beyond recycling. It has developed self-lubricating, high-performance polymers designed for extended service life, reducing the frequency of replacements and the overall volume of industrial waste. These advanced materials also remove the need for external lubricants, which can contaminate ecosystems, while maintaining reliable performance in demanding environments. Addressing growing concerns around chemical safety, igus has introduced PFAS-tested and PTFE-free options, offering what it describes as safer alternatives without compromising on performance. “This situation highlights how important it is to rethink how we use and dispose of plastics,” says Matthew Aldridge, Managing Director at igus in Northampton. “At igus, we believe sustainability must be built into the design of materials and systems. Our goal is to help industries move beyond single use thinking and toward long-lasting, recyclable solutions.” As international talks stall, igus is calling on other industries to join its push for innovation in sustainable engineering and to help build a future where plastics are part of the solution rather than the problem.
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10 | Plant & Works Engineering www.pwemag.co.uk August/September 2025 Insight Historically when energy costs and environmental awareness were lower, close attention wasn’t always paid to the air consumption on machinery. Designers typically selected pneumatic actuators based on a range of ad hoc criteria: what they had used before, what was on the shelf, “it looks about right”, looking at a simple pressure/force graph and up sizing by one diameter “just to be safe”. This means the actuators on many older machines are over specified and it is perfectly possible and correct to turn down the operating pressure and reduce the redundancy and wastage. Where is compressed air consumed on typical machines Compressed air on machines is not only consumed for driving pneumatic cylinders. Other typical areas include: Vacuum generators, nozzles and suction cups Air blasts and air guns Leakage and losses Each of these require individual consideration for optimised performance and air consumption. Optimising air consumption with vacuum generators Pneumatic vacuum generators utilise a venturi nozzle based on the Bernoulli principle to create vacuum by accelerating the air flow through a constricting nozzle. Nozzles within the generators are designed for individual operation or as elements within a multi-stage generator. Nozzles are specifically designed to achieve high levels of vacuum, high flows for short evacuation times or a general-purpose combination of both. Passing compressed air through a nozzle and straight to atmosphere is potentially a very high consumption element. Rethinking compressed air efficiency in machinery Lowering the energy consumption of machines, is good for the environment and good for our wallets – but is reducing the operating pressure of machines to 4 bar always the right way to achieve this? Festo has been advocating pressure reduction as a key element within an energy saving approach for more than 10 years. However, does this always make sense? Surprisingly perhaps, the answer is no. As with many things in life, the devil is in the detail. Whilst there can be very positive results, it might not be the right way in all cases. Steve Sands of Festo GB looks at recent research by Dr. Wolfgang Gauchel of Festo Corporate Research & Innovation Dept (Circular Economy and Efficiency). Catalogue data will identify the optimum supply pressure to achieve the flow and negative pressure required. Often vacuum generators are designed to provide the highest vacuum level at only 4 bar. Increasing the pressure to 6 bar does not draw a deeper vacuum level although the flow will increase. But the evacuation time is shorter because of a higher suction rate. Air blow guns and air blasts Air jets are used for ejecting parts from conveyor belts and housings. There are different ways to optimise the energy usage – either by concentrating the flow through nozzles or using a reservoir to increase the stored energy but only ‘blipping’ the pulse for a very short time. Air blow guns are commonly used for cleaning down and removing dust and particles. As well as being potentially dangerous they are also another high consumption element. Modern air blow guns are equipped with an in-built regulator dropping pressure to only 2 bar and have a safety tip with relief ports. Leakage and losses Leaks need to be eliminated wherever possible but clearly the higher the pressure, the bigger the losses. Dead volumes in pneumatic systems such as filling and exhausting long or large diameter pipe runs for every cylinder cycle are another cause of energy wastage. Mounting the valves closer to the actuators shortens pipe run lengths. Reducing pipe diameters can also help but will also restrict pressurisation and to a greater extent exhaust times, therefore they should be simulated or calculated to achieve the required performance. Energy losses also occur due to non-laminar and turbulent flows. Pipe friction and eddies due to tight radii or kinks or supersonic flows can all create further efficiency losses within pneumatic systems and are affected by the operating pressure. Options for new machine builds On new machine designs and builds reducing the operating pressure from say 6 bar to 4 bar may not actually reduce air consumption. If parts are correctly sized for the application – and this includes not only the actuator but also the tubing runs, fittings and air supply unit etc. then it may be better to stay at a higher pressure. For example, if you design a machine to operate at 4 bar pressure operation it will require larger diameter cylinders to obtain the same dynamic or force as a 6 bar machine, the tubing will be a larger bore to achieve the flow at a lower pressure differential. Larger actuators, mountings, tubing and fittings will usually cost more. In addition, larger cylinders will add weight to the machine (critical if it is adding to the payload of other actuators), and take up more space. Hmm… maybe this doesn’t sound such a good thing? Reducing pressure makes a big impact If all the machines and devices connected to a
Insight August/September 2025 www.pwemag.co.uk Plant & Works Engineering | 11 compressor system can operate at a reduced air pressure, not only can the local pressures be reduced but it’s possible to reduce the whole network pressure. Compressor systems may be optimised for a given pressure/flow demand and this must be considered. Lower network pressures mean less losses from leaks. Air networks need to be able to cope with peak demands and fluctuations, educing pressures and the peak flow capacity whilst potentially saving energy could cause pressure drops and lost production. Positive, pressure reduction can reduce energy consumption and CO2 It helps to compensate oversizing. If the pressure level at the output of the compressor is reduced, less electrical energy is needed. Air leakage is smaller when pressure is reduced. The backstroke pressure can be reduced, if no/less load needs to be moved. In green field applications, a reduction of energy consumption can be reached. But all components needs to be optimised for the lower pressure. Negative, pressure reduction causes different problems A well sized cylinder needs to be one size larger when pressure is reduced from 6 to 4 bar. A well sized 6 bar cylinder needs the same amount of air as a well sized 4 bar cylinder. All other components (Fittings, Tubes, Valves, Air preparation, …) also needs to be bigger. There is a need for more construction space. Larger components are in general more expensive than smaller. Most vacuum generators have their best evacuation time to reach a defined vacuum at 6 bar. In brown field applications the system needs to be analysed in detail, if a pressure reduction makes sense. Whole machine approach The best approach is to engage with specialist applications engineers that can support machine optimisation according to all your priorities – machine performance, build costs, lifetime costs, energy efficiency etc. We would also strongly recommend looking at the whole solution not just one function at a time. Even narrowing the discussion down to replacing air actuators with electric drives can be a false generalisation. For example, does it make sense to use a sophisticated electric gripper on the end of a pick and place system, if a pneumatic one can do the job? Unlike electric grippers, pneumatic grippers do not consume energy when exerting a constant force gripping a component. In most cases you can save 50-60% of the mass. This is critical at the ‘end-of-arm as it enables you to reduce the size of all the supporting actuators – rotary, X-Y and Z. The savings on the overall system can be dramatic in purchase and operating costs. The recommendation is to focus on what you want to achieve and let specialists such as Festo support you in the configuration of your machine. For further information please visit: https://www.festo.com/gb/en/PWE
Maintenance Matters Focus on: CMMS 12 | Plant & Works Engineering www.pwemag.co.uk August/September 2025 In the UK engineering sector, Computerised Maintenance Management Systems (CMMS) have long been regarded as tools for organising work orders, tracking asset histories and managing spare parts. For decades, they operated in relative isolation, quietly fulfilling their administrative purpose. Over the past five years, the landscape has changed sharply. A CMMS is now expected to integrate seamlessly with a growing ecosystem of connected sensors, enterprise systems and analytics tools. It is no longer just a database; it is becoming the operational hub of maintenance strategy. Predictive maintenance relies on continuous streams of live data, often generated by IoT devices attached to machinery. Energy efficiency targets require coordination between maintenance teams, building management systems and sustainability reporting. Multi-site engineering operations cannot function effectively without shared platforms capable of drawing in data from disparate sources. Yet despite this clear need, integration is still one of the sector’s most persistent and costly sticking points. Many CMMS deployments underperform, and integration is often the root cause. While older, proprietary systems do create technical obstacles, the bigger problems are usually tied to governance, planning and human factors. Most UK engineering firms have built up a patchwork of legacy CMMS platforms, specialist monitoring software and enterprise resource planning systems, each adapted over the years to fit local workflows. When a modern CMMS is introduced, connecting it to this heterogenous network is rarely straightforward. Asset identifiers may be inconsistent, work order categories might not align, and in some cases the underlying data structures are fundamentally incompatible. Projects are also frequently managed as IT installations rather than operational transformations, leaving integration as an afterthought. By the time data mismatches and quality issues are discovered, budget and schedule pressures encourage “quick fixes” that fail to deliver lasting value. The outcome is often a CMMS that works in isolation but cannot support predictive analytics, real-time planning or automated reporting. The consequences are wide-ranging. Without integration, decision-making relies on incomplete or outdated information. Predictive maintenance cannot draw on the full picture of equipment performance, planning processes miss procurement or staffing data, and sustainability reporting depends on laborious manual extractions from multiple sources. Operationally, poor integration leads to duplicated data entry, heavier administrative workloads and growing mistrust in the system. When engineers perceive the CMMS as slow, inaccurate or irrelevant, adoption drops and the quality of information declines in a selfreinforcing cycle. As UK engineering operations modernise, CMMS platforms are expected to integrate seamlessly with IoT, enterprise and analytics systems. Done well, integration transforms maintenance from record-keeping to strategic insight. Achieving this demands planning, data standards, security awareness and phased delivery to unlock efficiency, reliability and competitive advantage. PWE reports. How smart CMMS integration is reshaping UK engineering
Focus on: CMMS Maintenance Matters August/September 2025 www.pwemag.co.uk Plant & Works Engineering | 13 Building integration for value Organisations that succeed with integration approach it as a process of coordination rather than simply connecting one system to another. They work to ensure that data is structured consistently, accessible across the business and relevant to operational decision-making. This might involve harmonising asset hierarchies across all systems before integration begins, agreeing common definitions for fault codes, or mapping sensor data directly to maintenance triggers. The use of recognised data standards, such as ISO 14224 for equipment reliability or IEC 81346 for structuring principles, can make integration simpler and more sustainable. Some companies opt for CMMS platforms with open APIs, allowing secure, flexible data exchange without relying on proprietary vendor connectors - a practical advantage for engineering operations with diverse assets and a mix of old and new systems. Attempting to integrate every connected system at once can be risky and disruptive. Many organisations have found that beginning with a few high-impact links delivers better results. For example, integrating the CMMS with inventory management can improve spare parts availability and reduce downtime almost immediately. Once that connection is stable, further integrations with IoT sensors, condition monitoring platforms or building management systems can be layered on. This incremental approach reduces operational risk, spreads investment over time and ensures that early lessons feed into later phases. Technology alone does not guarantee success. Engineers and planners must understand how integrated data will improve their work or they may continue to rely on spreadsheets and informal reporting. Training, clear communication and governance structures that bring together IT specialists, maintenance teams and operational managers can build the shared understanding needed for adoption. Decisions informed by both technical expertise and day-to-day operational realities tend to produce systems that are both functional and useful. Integration also increases the surface area for cyber threats, particularly in sectors linked to critical infrastructure. Each new connection must be designed with security in mind, using measures such as network segmentation, multifactor authentication and encrypted data transfers. Compliance requirements, from GDPR to sector-specific regulations, should be addressed early in the process. Maintenance logs containing personal data, for instance, may require specific handling when shared between systems. Finally, measuring the outcomes of integration in operational terms helps secure long-term support. Improvements in mean time to repair, firsttime fix rates, stock availability and maintenance cost per unit of output are indicators that integration is delivering value. By focusing on these results rather than technical milestones alone, organisations can demonstrate return on investment and build the case for further work. Ultimately, the integration of CMMS into the wider digital environment is no longer an optional enhancement for UK engineering firms; it is a core capability. Achieving it demands more than technical compatibility: it requires coordinated planning, adherence to data standards, phased delivery and close collaboration between departments. When done well, integration transforms the CMMS from a passive record-keeping tool into a central driver of efficiency, reliability and strategic insight - a shift that can define the competitive edge in an increasingly connected industrial landscape. Name: Company Name: Address: Post Code: Tel: Total Number of Copies @ £ p+p Total £ Drives S & S Hyd H/B Pne H/B Ind Mot Comp H/B H/B Air QUANTITY QUANTITY Hydraulics & Pneumatics There are now 6 of these handy reference books from the publishers of the Drives & Controls and Hydraulics & Pneumatics magazines. Published in an easily readable style and designed to help answer basic questions and everyday problems without the need to refer to weighty textbooks. We believe you’ll find them invaluable items to have within arms reach. From the publishers of QUANTITY QUANTITY QUANTITY 2-5 copies £4.30, 6-20 copies £4.10, 20+ copies £3.75. QUANTITY PRACTICAL ENGINEER’S HANDBOOKS HYDRAULICS INDUSTRIAL MOTORS SERVOS AND STEPPERS PNEUMATICS COMPRESSED AIR INDUSTRIAL ELECTRIC DRIVES PLEASE ALLOW UPTO 28 DAYS FOR DELIVERY $&! -!.5&!#452).' -%$)! ,4$ 4HE (IGH 3TREET 4ONBRIDGE +ENT 4. "% Postage and Packaging: 1-3 copies: £2.99 4-6 copies: £4.99 7 or more copies: £6.99 If you would like to obtain additional copies of the handbooks, please email info@dfamedia.co.uk or call us on 01732 370340. Alternatively you can return the completed form below to: Engineers Handbook, DFA MANUFACTURING MEDIA LTD, 192 The High Street, Tonbridge, Kent TN9 1BE #HEQUES SHOULD BE MADE PAYABLE TO $&! -ANUFACTURING -EDIA ,TD AND CROSSED ! # 0AYEE #OPIES OF THE HANDBOOKS ARE AVAILABLE AT a PER COPY $ISCOUNTS ARE AVAILABLE FOR MULTIPLE COPIES
Maintenance Matters Focus on: OEE 14 | Plant & Works Engineering www.pwemag.co.uk August/September 2025 OEE and the circular economy The EU has set its sights on carbon neutrality by 2050. The big question for manufacturers is: will your operations accelerate that future or hold it back? Thomas Feßl, Business Development Manager at automation supplier COPA-DATA, explores the importance of OEE for manufacturers looking to align with circular economy principles. The circular economy is a broad, systems-level approach to production and consumption that aims to keep materials, products and resources in use for as long as possible. It goes beyond recycling: it’s about designing out waste, maintaining value and closing material loops through reuse and remanufacturing. In manufacturing, this means rethinking not just what we produce, but how we produce it and how we can do so with fewer inputs, less waste and longer product life. From tracking materials to reuse models and reverse logistics, circularity requires change on many levels. One key metric to focus on in this transformation is Overall Equipment Effectiveness (OEE). OEE offers a powerful way for manufacturers to address core goals such as waste reduction, efficient use of resources and optimized asset performance - all of which lay the groundwork for a more circular future. Europe has made progress towards circularity by successfully decoupling economic growth from resource use and maintaining high resource productivity at over €2/kg since 2015. However, there is still work to be done. With 14 tonnes of material use and five tonnes of waste per person yearly, the challenge is huge. Recognising the need for action, in 2020 the European Commission launched the Circular Economy Action Plan (CEAP), a core element of the European Green Deal, that is pushing for smarter use of raw materials and tighter resource cycles across all industries. The plan seeks long-term sustainability while pressuring businesses to adapt and prove progress with data.? Economic forces are also pushing in the same direction. Energy prices remain volatile, global supply chains are fragile and margins are under pressure, making resource efficiency an economic imperative. From insight to action So where do manufacturers start? One powerful metric is Overall Equipment Effectiveness (OEE). Creating more value with fewer resources - extending product life and reducing waste — is central to the circular economy. OEE provides a practical framework to put these goals into practice on the factory floor. A circular economy not only supports sustainability but also drives operational efficiency - helping companies become more economically resilient in the process. Widely considered the gold standard for productivity monitoring, OEE offers a measurable way to improve efficiency and enable circularity. It monitors how well a manufacturing process performs by combining three core factors: availability, performance and quality. These factors are distilled into a percentage that helps businesses to identify and address potential areas of waste. Poor OEE can lead to unplanned downtime that causes excess waste, energy spikes from equipment restarts and machinery wear. Increasing availability can prevent this.
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16 | Plant & Works Engineering www.pwemag.co.uk August/September 2025 Maintenance Matters Focus on: OEE Improving performance ensures optimal speeds and reduces micro-stoppages that may lead to overproduction or excessive energy use. Optimizing quality directly limits scrap rates and rework, thus conserving materials and reducing emissions associated with defective units. Data-driven optimisation Making real sustainability gains through OEE takes more than just periodic reporting. Realtime, high-resolution visibility across the production line is essential. Today’s manufacturers are increasingly embracing technologies like automation software and IoT platforms to gather detailed, granular data from production systems. Teams can monitor OEE metrics, detect cycle slowdowns or quality issues, and respond immediately. This kind of visibility can inform predictive maintenance, reduce material waste and even improve energy load balancing across shifts. And with historical trend data, manufacturers can support continuous improvement (CI) and statistical process control (SPC) initiatives. Linking OEE with live data makes it possible to measure sustainability in real terms - like specific energy consumption or carbon intensity per unit — and take targeted action. Lean and green management Lean manufacturing principles are increasingly recognized as effective tools for improving CE outcomes. Lean manufacturing is all about doing more with less — streamlining processes, cutting out waste and focusing only on steps that truly add value to the product - and OEE is a key part of this. As a unified metric, OEE quantifies the impact of both lean and green initiatives in a single performance model. Lean methodologies focus on eliminating overproduction, delays and excess motion. Green goals target energy consumption, emissions and material throughput. OEE links these challenges, making it possible to assess key drivers like the effectiveness of changeovers, downtime events and first pass yield in real time — all important elements of lean and green principles. Reducing changeover time boosts takt time and limits material waste during transitions. Firstpass yield helps to reduce rework cycles to save on both energy and raw inputs. Real-time dashboards make it easier for teams to model the direct correlation between improved OEE and reduced environmental footprint. This helps meet production and sustainability targets. OEE strategies that work Companies are using OEE strategies aligned with CE principles and seeing impressive results. Handl Tyrol, a speck producer, used COPADATA’s zenon software platform to monitor realtime data. This helped to reduce downtime and support precise resource usage while also improving its energy efficiency and OEE percentage, aligning perfectly with the company’s sustainability goals. Meanwhile, White Panther, a prawn farm in Austria, used zenon to optimize process parameters in its indoor aquaculture operation. The facility operates with a self-sufficient energy and heat supply, powered by hydroelectric and biomass systems from its own resources. As well as generating 30 GWh of electricity a year — enough to power the entire town of Rottenmann — the system makes use of wasted production heat. This residual heat is now used to keep all 56 tanks at a constant 28°C — essential for optimum prawn growth. By closely tracking equipment performance and responding rapidly to process deviations, it improved overall efficiency while minimizing water and energy consumption. To meet climate goals, moving towards a circular economy is critical. Manufacturers must adopt strategies to not only enhance their performance, but centre sustainability too. OEE is a valuable tool to bridge the gap between the two and support lean processes and green goals. By monitoring and optimising OEE, businesses can work smarter, waste less and build a circular, more sustainable future. Looking ahead OEE is a valuable tool in the shift toward circular manufacturing - but it is only one part of a much larger puzzle. Truly circular systems require attention to design, supply chain coordination, and reuse strategies. By focusing on efficiency and performance at the equipment level, manufacturers can lay a strong foundation for further circularity efforts. The journey toward a circular economy is ongoing - and starts with smarter operations today. For further information please visit: www.copadata.com
Award Programme Partners The BPMA’s annual Pump Industry Awards programme has been recognising and rewarding the achievements of pump businesses, large and small for over two decades. Throughout that time it has become one of the leading events to serve the industrial and commercial arena. So, if you or your company have a pump related success to shout about, these awards provide the perfect platform. The gala presentation dinner caps off the awards programme in style, providing excellent networking opportunities, great food and superb entertainment. It’s your chance to celebrate with colleagues, interact with peers, entertain customers and be part of the pump industry’s biggest and best celebration. Manufacturing and distribution prowess, product development and application, environmental consideration, skills development and customer support will all be acknowledged through this wide reaching awards programme. So why not consider which of your engineering successes are deserving of industry wide recognition, and be sure to join us at our wonderful venue - the home of English football - on Thursday 19th March 2026. PUMP INDUSTRY AWARDS 2026 Recognising and Rewarding Excellence Lee Tebbatt, BPMA President, says of the Pump Industry Awards,“The pump industry has long been a hotbed of innovation, with manufacturers striving for engineering excellence to deliver greater operational performance and improved efficiencies to its broad customer base. The industry landscape is changing and as a collective, we’re moving the dial on important issues such as water scarcity, energy shortage and climate change, we’re driving sustainability across our supply chains and we’re sharing best practice among our members. This BPMA backed awards programme brings the pump industry together in celebration of this drive for industry excellence. Event Calendar Nominations Open: 1st July 2025 Nominations Close: 28th November 2025 Judging Session: Mid December 2025 Voting: 12th – 16th January 2026 Winners Announced: 19th March 2026 www.pumpindustryawards.com Organised by on behalf of Venue: Hilton at St George’s Park, Burton upon Trent Date: Thursday 19th March 2026 NOMINATIONS CLOSE 28TH NOVEMBER Will you be crowned a winner in 2026?
Maintenance Matters Problem Solver 18 | Plant & Works Engineering www.pwemag.co.uk August/September 2025 Wangen Pumps has enhanced the design of its Twin NG pump, which the company says is significantly improving its performance and reducing maintenance requirements. The result is a hygienic pumping solution that performs better for longer, boosting uptime and reducing lifecycle costs for customers in the food, pharmaceuticals and cosmetics manufacturing sectors. Martin Stümpfle, Product Management Wangen Pumps, explained: “We are constantly seeking ways to improve pump performance and benefit our customers’ operations. The technical improvements we have made to our popular Twin NG pump deliver advantages ranging from contamination risk reduction to longer service life.” Twin NG screw pumps are designed to reliably handle low to highly viscous, volatile, or gaseous products in applications that demand maximum hygiene and efficiency. Available in several sizes, the Twin pumps offer a maximum flow rate of 200 m?/h and a maximum differential pressure of 25 bar. The first design enhancement involves replacing the Twin NG’s motor coupling with a lantern coupling. This feature prevents pump shaft misalignment, which reduces stress and vibration, thereby enhancing the lifespan of the pump and motor. With less wear on pump shafts and bearings, maintenance requirements are minimised, and service intervals are extended. When maintenance is necessary, it is easier to perform since no shaft alignment is required. This lantern design thus lowers the total cost of ownership (TCO) and optimises uptime. Another benefit of the new lantern design is smoother operation in demanding conditions, particularly where the Twin NG is used to pump viscous and abrasive fluids under high pressure. The lantern coupling also enables better sealing arrangements, minimizing leaks and the risk of product contamination. The second design improvement to the Twin NG pump is the option to install the pump using hygienic machine feet instead of a base plate. These feet are much easier to clean than traditional base plates because they minimise surfaces where dirt and bacteria can accumulate, greatly reducing the risk of hidden contamination associated with solid base plates. The individual feet also facilitate more effective wash-down and drainage, without the need for elaborate drainage slopes and holes. Like the pump’s lantern coupling, the machine feet help to dampen noise and vibration, reducing wear on the pump and associated equipment. Individually adjustable, machine feet enable precise levelling, making it easier to align the pump with existing piping and reducing the risk of errors during installation. The feet also provide better access to the pump during routine maintenance, whereas base plates may require disassembly before vital components can be reached. Machine feet therefore improve pump availability by reducing servicing time. Additional benefits of machine feet include a better ability to compensate for thermal expansion, preventing damage to the pump and piping, as well as better stability during maintenance at the pump’s fluid end. Furthermore, machine feet generally require less room than a base plate, which is important in confined spaces. Eliminating the base plate also reduces material and fabrication costs, making pump transportation and handling easier. Stümpfle concluded: “The improved Twin NG exemplifies our commitment to listening to our customers, understanding their business needs, and refining our pump designs to deliver improvements in performance, cost and serviceability that contribute to greater overall efficiency and productivity.” For further information please visit: www.wangen.com Upgraded Twin NG pump offers longer service life and easier maintenance Wangen Pumps’ upgraded Twin NG pump solution features design enhancements that the company says boosts performance, extends service life, and simplifies maintenance, supporting greater hygiene, uptime, and efficiency in food, pharmaceutical, and cosmetic manufacturing. PWE reports. Wangen Pumps has enhanced the design of its TWIN NG pump, significantly improving performance and reducing maintenance requirements in hygienic pumping applications.
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