NEWS | FEATURES | PRODUCTS | CASE STUDIES www.pwemag.co.uk @PWEmagazine1 Smart maintenance starts with cybersecurity Inside this issue: 20 > Out of sight not out of mind 26 > Making systems work together 30 > Driving performance in food processing page 12 @plant-&-works-engineering PWE Plant & Works Engineering Since 1981 October/November 2025 | Issue 489
Decentrally distribute 24 volts Centrally monitor with IO-Link ifm.com Configurable voltage and electronic circuit breakers for each supply channel A 12-segment LED bar graph displays the current demand of the overall system as well as the current demand of each channel Protected current distribution with less loss for both sensors and actuators Robust IP65/IP67 housing for installation without control cabinet in the field
As the UK approaches the November 2025 Budget, industry will be looking for direction rather than rhetoric. Why this Budget matters As the UK approaches the November 2025 Budget, industry will be looking for direction rather than rhetoric - this is more than an accounting exercise. The decisions made will influence how quickly plants modernise, how efficiently assets are managed, and how confidently companies invest in productivity and growth. Digital technology is already transforming maintenance practice. Predictive analytics, automation and connected systems are reducing downtime and extending equipment life. These advances are becoming routine in some facilities, but progress across the wider industrial base remains uneven. Many smaller firms still face barriers to investment because of Editor’s Comment ‘ ’ cost pressures, limited skills or inadequate digital infrastructure. The Budget could help to close that gap by giving businesses the confidence and conditions needed for consistent modernisation. Meaningful incentives would make a real difference. Extending full expensing or offering enhanced capital allowances for automation, robotics, sensors and condition-monitoring equipment would encourage companies to invest in systems that improve reliability and efficiency. Targeted support for industrial digitalisation, including data integration, connectivity and cybersecurity, would help ensure that advanced maintenance technology becomes achievable for a wider range of operators rather than a select few. Skills are the thread that ties everything together. As equipment becomes more intelligent, maintenance work increasingly depends on a mix of mechanical, electrical and digital expertise. Expanding funding for apprenticeships, retraining and midcareer development would help the workforce adapt as technology evolves. Regional training partnerships between government, industry and education providers could make this support easier to access, especially for smaller companies. For these measures to work, policy stability is essential. Frequent changes in incentives or priorities make longterm planning difficult and discourage investment. A clear and consistent framework for industrial development would give businesses the confidence to focus on improvement rather than survival. Maintenance professionals rarely feature in Budget headlines, yet their work underpins every sector the government wants to strengthen. If the Chancellor can deliver a plan that supports investment, skills and innovation, UK industry will be better equipped to modernise and compete. The technology is ready, the capability exists, and the ambition is there. What matters now is whether policy will keep pace. October/November 2025 www.pwemag.co.uk Plant & Works Engineering | 03
October/November 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 express6the 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. Contents 10 34 20 27 BCAS official media partner Audit Bureau of Circulation – Average net circulation 10,274 January 2024 to December 2024 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 Smart maintenance depends on connected systems, automation, and remote access but these same technologies also increase exposure to cyber threats. With the UK’s Cyber Security and Resilience Bill and the EU’s NIS2 Directive setting higher expectations, manufacturers must embed cybersecurity into every layer of maintenance to protect uptime and resilience. Maria Else explains further. PROCESS, CONTROLS, & PLANT 20 Focus on: Compressed Air/ Pumps & Valves Compressed air is essential to industry yet often overlooked. Regular maintenance, monitoring, and workforce training can improve reliability and efficiency while reducing energy losses and operating costs, PWE reports. ENERGY & ENVIRONMENTAL MANAGEMENT 26 Focus on: Boilers, Burners & Controls/ Cooling Boilers remain central to many industrial plants — reliable and familiar, but often ignored until problems arise. As automation advances, their control systems are evolving rapidly. HANDLING & SAFETY MATTERS 30 Focus on: Handling & Storage SPECIAL FOCUS SUSTAINABILITY 34 INDUSTRIAL SECURITY 36 WIND ENERGY 38 PRODUCTS & SERVICES DIRECTORY 42
News 6 | Plant & Works Engineering www.pwemag.co.uk October/November 2025 The ERA Foundation has marked its 25th anniversary by celebrating more than two decades of investment in engineering and manufacturing engagement, including the funding of hundreds of projects worth over £20 million, and by awarding the 2025 Clark Prize to four teachers across the UK. At a special event at the Royal Society in London, Sir John Lazar CBE FREng, President of the Royal Academy of Engineering, gave a keynote speech on the Academy’s strategy and focus on skills for engineering. He was joined by ERA President Sir Alan Rudge CBE FREng, Chair Andrew Churchill OBE FREng, and 130 guests to toast the support of a long list of pro-engineering activities, from value-creating enterprise hubs to engineering fellowships and teachers whose work has showcased engineering to school children across the UK. Sir John emphasised the importance of inclusive skills evelopment: “Equity, diversity and inclusion is a vital thread through all three goals [of the Academy’s strategy] because we can’t talk about delivering positive outcomes for people without talking about how engineering designs for all of society, and how engineers therefore need to reflect all of society.” The Foundation has played a central role in shaping engineering opportunities, from funding 55 industrial fellowships and over 100 Arkwright Engineering Scholars, to helping establish the Royal Academy of Engineering Enterprise Hub. Ranked among the top three enterprise hubs in the UK and 14th in Europe by the Financial Times and Statista, the Hub has supported over 600 researchers and entrepreneurs and contributed to nearly 6,000 jobs. Highlighting the Foundation’s reach into schools, the annual Clark Prize - named after former ERA Executive Secretary Dr David Clark - recognised four inspirational teachers for their commitment to bringing engineering into the classroom. Lucy Hart of Caroline Haslett Primary School in Milton Keynes and Tracey Ellicott of East Wemyss Primary School in Fife won the primary category, while Clare Doherty of St Mary’s College, Derry, and Dewi Thomas of YGG Bro Edern in Cardiff won at secondary level. Each school receives £12,000 over three years to support their STEM engagement projects, with the teachers also receiving individual awards. This is the first year that the prize has been awarded to two teachers per category, and the first time that schools from all four nations of the UK are represented. “The winning teachers of this year’s Clark Prize are outstanding; it is quite overwhelming to see the amount of work they devote to connecting engineering and manufacturing with school pupils,” said Andrew Everett, executive secretary of the ERA Foundation. “Their biographies speak for themselves. The Clark Prize will continue to identify and reward hard-working STEM teachers and schools, and we know there are many more out there.” Churchill added: “It is very exciting to celebrate the commencement of our 25th year of the ERA Foundation. We are very privileged to be custodians of a foundation that has the means to support such an array of brilliant projects right across the spectrum, from big investments like the Royal Academy of Engineering’s ‘Enterprise Hub’, which has funded over 600 entrepreneurs, to the primary schools of teachers such as Lucy Hart and Tracey Ellicott, who infectiously share the excitement of engineering with school children from a young age.” Dr Hayaatun Sillem CBE, CEO of the Royal Academy of Engineering, said: “We congratulate the ERA Foundation on its inspiring work to promote and enable future engineering innovation and skills over the last quarter of a century. I am delighted to be able to work with this farsighted organisation, which has played such an active role in supporting the work of our Academy and particularly our successful and growing Enterprise Hub.” Since its founding, the ERA Foundation has collaborated with a wide range of partners, from STEM Learning and EngineeringUK to the Smallpeice Trust, while also embracing digital platforms such as Born to Engineer to connect new generations with careers in engineering. With its influence now stretching across research, enterprise, schools and social media, the Foundation remains a quiet but powerful force in advancing UK engineering. ERA Foundation marks 25 years with celebration of engineering and Clark Prize for teachers The Association of Electrical and Mechanical Trades (AEMT) marked its 80th Anniversary with a new-look annual conference that drew a record number of delegates, making it the largest event in the Association’s history. Held at the British Motor Museum in Gaydon, the conference featured a programme combining keynote speakers, panel discussions, and technical sessions, alongside an exhibition with more than 20 exhibitors from across the electromechanical repair sector. Jim Fowlie of SensorWorks said the event provided stronger engagement than previous years: “We have had more meaningful conversations with the attendees today than in previous years, and in more depth. It has certainly been a worthwhile day.” The keynote address was delivered by Mark ‘Billy’ Billingham, who shared stories from his upbringing and 20-year career in the Special Air Service (SAS), focusing on resilience in business and the importance of “always a little further,” the SAS motto. A panel discussion on succession planning followed, featuring Gary Downes (EMiR Software), George Knowlton (Knowlton & Newman, a Rubix Company), Jack Dunning (IPS Newcastle) and Shaun Sutton (Central Group). The panellists discussed ownership transitions in their organisations and took Record attendance marks AEMT’s 80th Anniversary conference
News October/November 2025 www.pwemag.co.uk Plant & Works Engineering | 07 Every year, Make UK does a survey on investment trends in manufacturing. The results of the 2025 survey are especially noteworthy as it shows the announcement of a long term industrial strategy is set to bring immediate benefits to the UK economy, with more than a third of manufacturers saying they will now accelerate investment projects as a direct response. In addition, the positive commitments the Government has made in the Advanced Manufacturing Plan are highlighted by the fact that three quarters of companies believe they will benefit directly from it. The figures will provide a timely boost in the run up to the Budget as investment intensity (investment as a % of turnover) has dropped sharply in the last year in response to domestic and overseas uncertainty and is now the lowest since the immediate aftermath of the EU referendum at 6.8%. This is down significantly from last year when it reached a ten-year high of 8.1%. R&D intensity has also fallen slightly to 6.2% from 6.5% last year. As a result, in the run up to the forthcoming Budget, Make UK will be urging the Government to not just safeguard vital investment incentives which the survey shows are key drivers of manufacturers’ investment decisions but, extend them further. According to the survey, almost four in ten companies (37%) make their investment decisions based on the availability of tax reliefs. Furthermore, Make UK is also urging the Government to set in stone the business tax relief policy for the remainder of this Parliament given almost a third of companies (31.8%) say frequent changes to tax relief policy are acting as a barrier to investment. As well as analysing the impact of Government policy, the survey also provides a comprehensive view of investment trends across UK manufacturing. The announcement of an industrial strategy being specifically used to drive investment in decarbonisation by more than 4 in 10 companies (43.%). Investment in data analytics and AI (35.4%) and increased manufacturing capacity (34.2%) are a priority for around a third of companies. Skills has overtaken plant and machinery as the leading investment priority in the next twelve months (47.6% and 44.1% respectively). Amid the ongoing debate about the investment performance of UK industry compared to international competitors, almost two thirds of companies (68%) invest up to 10% of their turnover in plant and machinery, with a further fifth (18%) investing between 10% and 50%. Furthermore, more than two thirds of companies (68%) invest up to 10% of turnover in R&D, while almost one in five (18%) invest between 10% and 50%. Despite the overall encouraging picture, it’s clear that manufacturing investment is at a critical juncture. It’s therefore essential that the Government does all it can to focus on growth and investment as a matter of urgency. By MAKE UK chief executive, Stephen Phipson MAKE uk - the manufacturers’ organisation monthly news comment questions from the audience. In the afternoon, Dr Paul Bedford presented on staff retention, highlighting generational differences in workplace expectations and the need to reflect these in recruitment and retention strategies. A Women in Engineering Power Hour provided a forum for female members to discuss findings from a recent survey on their experiences in the sector and to explore how the AEMT can better support women in the future. Simultaneously, Karl Metcalf, AEMT Lead Trainer and Technical Advisor, hosted a Condition Monitoring panel with Will Ocean (Maintain Reliability), Matt Fletcher (Fletcher Moorland) and Fernando Velloso (WEG). The group discussed the growing importance of condition monitoring, integration with planned maintenance, and the potential role of artificial intelligence. The final session saw AEMT Council members Andy Patten and James Stevens provide an update on discussions with the Electrical Apparatus Service Association (EASA) regarding potential collaboration between the two organisations. This was followed by a presentation from Frédéric Beghain, General Manager of EASA’s Europe, Asia and Africa Chapter, outlining EASA’s work and the benefits it offers members. Reflecting on the day, AEMT General Manager Thomas Marks commented: “I’m delighted with what the team has been able to deliver for our members here today, it was a fitting recognition of the Association’s 80th anniversary. It is important that we recognise the immensely positive impact our Association has had in its eight decades as we look to what promises to be an exciting and rewarding future for its membership.”
News 08 | Plant & Works Engineering www.pwemag.co.uk October/November 2025 Manufacturing and Engineering company, igus UK, has been recognised for its exceptional commitment to employee health and wellbeing, taking home the Gold Award in the “Healthy Food & Wellbeing – Workplace” category at this year’s Weetabix Northamptonshire Food & Drink Awards. The prestigious awards ceremony, held at the Royal & Derngate in Northampton, celebrated the very best of Northamptonshire’s thriving food, drink, and hospitality scene. Now in its 17th year, the event shone a spotlight on 18 categories of excellence, highlighting innovation, sustainability, and dedication across the county. Sponsored by Delapré Abbey Preservation Trust, the Healthy Food & Wellbeing Workplace Award recognises organisations that go above and beyond to promote healthier lifestyles and positive workplace cultures. igus UK, based in Brackmills, Northampton, impressed the judges with its proactive approach to wellbeing demonstrated by the integration of nutrition, fitness, and mental health initiatives into everyday working life. Purchasing manager Anita Holt says “We are incredibly proud to receive this award, which reflects our ongoing commitment to the wellbeing of our people. At igus, we believe that a healthy workplace is the foundation of a thriving business, and we’re delighted that our efforts have been recognised alongside so many other inspiring local organisations.” The Gold Award acknowledges the continued investment from igus in health-focused initiatives, including wellness days, nutritious food offerings, employee fitness programmes, and open conversations about mental wellbeing. Awards Director, Rachel Mallows MBE DL, praised all category winners for their innovation and dedication: “Northamptonshire’s food and drink scene is a true community effort - from independent cafés and artisan producers to family-run farms and larger local partners. Together, they create experiences that connect people, celebrate creativity, and keep our county buzzing with flavour and innovation.” For igus UK, the award reinforces its commitment not only to engineering excellence but also to being a workplace where people feel valued, supported, and motivated to thrive. igus wins gold at Weetabix Northamptonshire Food & Drink Awards Combilift re-qualifies for Deloitte Best Managed Companies Award for 13th consecutive year Irish manufacturer Combilift has been recognised once again as one of Ireland’s Best Managed Companies by Deloitte, marking its 13th consecutive year receiving the distinction. The recognition follows a detailed requalification process designed to assess organisations across four key performance areas: strategy, culture and commitment, capabilities and innovation, and governance and financials. The process requires previous awardees to demonstrate continued excellence and leadership in a changing global business environment. According to Deloitte, the programme identifies companies that show sustained strategic focus and operational effectiveness over time. “The renowned Deloitte international brand Best Managed Companies programme sets a high benchmark, and requalifying for the 13th time reinforces our position as a serious global business,” said Martin McVicar. “While we’re known for manufacturing innovative world-class material handling solutions, this recognition also speaks to how we run our business — from our lean operations and customer-focused R&D to our world-class production facility in Monaghan.” Combilift, founded in Monaghan in 1998, has grown into a major global producer of multidirectional forklifts and material handling solutions. The company’s continued presence on the Best Managed Companies list reflects its long-term focus on innovation, efficiency, and strategic management. Deloitte’s programme is part of a global network recognising private companies that demonstrate strong business performance and organisational culture. Combilift’s requalification underscores its ability to maintain high standards of governance and performance across multiple business cycles.
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10 | Plant & Works Engineering www.pwemag.co.uk October/November 2025 Insight From farms and factories to complex industrial plants, hydraulic systems are the quiet workhorses of the UK economy. They keep production lines moving, power essential machinery, and underpin countless critical operations. But as the sector evolves, businesses are recognising the need for greater consistency in quality, testing, and training to keep pace with rising demands on performance and safety. Too often, hoses and fittings are mismatched. Too often, parts are bought on price alone, with little attention paid to certification. And too often, the people assembling and maintaining these systems have learned through trial and error, without formal guidance. It is a combination that can work, until it doesn’t. Failures bring downtime, costly repairs, and in the worst cases, life-changing injuries. That is the backdrop against which Evofluid Putting training and quality at the heart of hydraulics PWE’s Aaron Blutstein speaks to Stefan Gunter, Business Development Manager at Evofluid Hydraulics UK, and Alberto Gogazzi, Area Sales Manager at Oleodinamica & Pneumatica (O&P), about their new partnership. They discuss how the collaboration aims to tackle longstanding challenges in the hydraulics sector, from mismatched assemblies, re-ending, and inconsistent training to the need for locally supported, high-quality solutions that improve safety, reliability, and efficiency across the industry. Hydraulics UK and Oleodinamica & Pneumatica (O&P) have launched a partnership aimed not just at supplying products, but at helping the industry rethink its approach to safety, efficiency, and competence. “It’s about more than supplying parts or machines,” says Stefan Gunter, Business Development Manager at Evofluid Hydraulics UK. “Our industry needs to think in terms of systems, where every component is matched, tested, and supported, and where the people using those systems have the knowledge to do their jobs safely and effectively.” Catastrophic consequences The case for change is stark. Stefan describes a past visit where the fittings being used “looked fine on the bench” but had no testing records, no certification, and no way to prove compatibility. “I’ve seen situations where an operator asks their supplier for documentation and gets nothing,” he says. “That lack of traceability is a real risk. You don’t know what you’re fitting, or what it’s been tested for.” The consequences of that uncertainty are all too real. “If you’ve ever stood next to a hose when it fails under pressure, you’ll know how serious it can be,” says Stefan. “A few years ago, I witnessed the aftermath of a case where the wrong pressure rated adaptor had been used to test a hose. When it failed under full pressure, the bang shook the building - it was like an explosion. The Perspex on the test rig shattered, with shards narrowly missing the operator. “The operator was frozen in shock. He was barely able to speak with the shock for a day or two afterwards. Thankfully, nobody was hurt, but many people haven’t been so lucky. There
Insight October/November 2025 www.pwemag.co.uk Plant & Works Engineering | 11 have been countless serious injuries and even fatalities in the industry from hydraulic failures. “And it’s not just the immediate danger. Think about the indirect consequences. If a hose fails in a lift, on agricultural machinery, or even on a plane, the risk to people and equipment multiplies. It’s simply not worth cutting corners when the stakes are that high.” A system, not a shopping list The partnership between Evofluid and O&P is designed to tackle those issues head-on. Evofluid serves as the UK commercial branch of Hydro Holdings S.p.A., a European manufacturer of carbon steel and stainless-steel hydraulic components. This strategic position gives Evofluid the ability to maintain strict quality control and deliver quickly from extensive UKbased stock. By combining that local manufacturing strength with O&P’s 44 years of expertise in hose and tube processing equipment, the two companies offer something many operators say they need but rarely find: a complete, end-toend system. O&P’s machines - crimpers, cutters, skivers, flushing rigs, and test rigs - are engineered for reliability and ease of use. The grease-free crimping heads and fixed six o’clock die positions make operations faster and more consistent, while Siemens touchscreens, fully supported in the UK, allow quick backups and cost-effective repairs, reducing downtime. “It’s about giving customers confidence,” Stefan explains. “Confidence that the components they’re using are certified, that the assemblies are matched and tested, and that the equipment they’re working with is dependable and supported locally.” Training as a foundation, not an add-on Evofluid and O&P see training not as an optional extra but as the foundation for safer, more efficient operations. They have committed to a programme to offer subsidised, BFPAaccredited courses designed to embed knowledge and best practice across the sector. Flexibility is key: courses can be delivered onsite, online, or at a training centre, making them accessible whether you are a one-person workshop or a major industrial operator. The training courses includes: Hose assembly skills – Core techniques for building safe, consistent assemblies. Hose integrity, inspection, and asset management – Identifying wear, preventing failures, and extending service life. Hydrostatic proof pressure testing – Proper testing procedures for certification and quality assurance. Level 2 hydraulics and Level 1 pneumatics – Building deeper technical understanding for technicians and engineers. Leadership and management academy – Equipping supervisors to drive a culture of quality and safety in their teams. “Training isn’t optional,” Stefan says. “When a technician understands not just what to do but why it matters, you get better assemblies, fewer failures, and safer workplaces. That knowledge pays for itself many times over.” Beyond the classroom Structured courses are only part of the offer. Evofluid and O&P are building what Stefan calls “continuous support”, with tools and services that help businesses maintain high standards long after the training day ends. This includes: Hose health checks to identify risks early. Cost-effective machine calibrations in line with BFPA recommendations. Technical guidance for hose production and asset management. Safety literature, including standards cards, quick-reference posters, and fluid injection guidance. Support for hose restraint systems such as Stopflex+. “Training has to be ongoing,” Stefan explains. “You don’t create a safety culture with a single session; you do it by making learning part of the job, by keeping people informed and confident every day.” Alberto Gogazzi, Area Sales Manager at O&P Srl, agrees: “Selling quality products is important,” he says, “but supporting customers with knowledge is what builds trust. That’s what drives long-term change.” The partnership also tackles a technical problem that has plagued the industry for years: mismatched assemblies. By integrating Evofluid’s certified fittings, including the OneGC stainlesssteel ferrule, compatible with up to ten different hose types, with O&P’s precision machinery, operators can build assemblies that are consistent, compliant, and easier to maintain. Lean production and efficiency Safety is only part of the story. The partnership is also about efficiency. Evofluid’s Lean Production Guarantee, which focuses on eliminating waste, improving processes, and maintaining quality, has helped customers cut downtime and reduce errors, with some seeing cost savings of up to 30%. Inventory simplification is a key part of this. “When you can reduce the number of SKUs without compromising compatibility, you make the process leaner and less prone to mistakes,” Stefan explains. O&P’s machines play their part too. Greasefree crimping heads and fixed six o’clock die positions make operations faster and more consistent, while Siemens touchscreens, fully supported in the UK, mean data can be backed up quickly and parts replaced without the delays that often come with overseas support. Local support, faster response For many UK operators, the weakest link has been service and support. When machines fail, waiting weeks for overseas parts or technicians can turn a minor fault into a major disruption. Evofluid has invested in UK-based stock and trained service technicians to close that gap. “When a machine goes down, you can’t afford to wait weeks for help,” Stefan says. “By having parts and expertise here in the UK, we can get customers back up and running quickly and cost-effectively.” For both Evofluid and O&P, this partnership is about more than commercial growth. It is about raising standards across the industry. “This isn’t just about our customers,” Alberto says. “If we can help raise standards for everyone, operators, suppliers, and end-users, that benefits the entire sector. Quality, compatibility, and training shouldn’t be optional. They should be the baseline.” Stefan agrees: “This is about investing in the future. Safer systems, leaner processes, and better-trained teams don’t just make sense for today, they build resilience for tomorrow.” Investing in a safer, smarter future In an industry where cost pressures are everpresent, the temptation to cut corners is everpresent unfortunately. But as Stefan points out, the long-term risks far outweigh the short-term savings. A mismatched fitting or an untested assembly doesn’t just threaten equipment, it puts people, productivity, and reputations on the line. By embedding training and continuous support alongside matched systems and locally backed equipment, Evofluid and O&P are reframing what good practice looks like. They are making quality and safety accessible, scalable, and sustainable for businesses of every size, from independent workshops to major industrial operators. Stefan puts it simply: “Training isn’t about selling. It’s about building trust and giving people the tools to do their jobs safely and effectively. If we can help raise standards, not just for our customers but across the industry, that’s a win for everyone.” For operators, the message is clear: investing in quality, compatibility, and competence isn’t a luxury. It is the foundation of safer, leaner, and more resilient operations. And for an industry where failure can carry such high costs, that investment has never mattered more. For further information please visit: www.evofluid-hydraulics.com or www.op-srl.it
Maintenance Matters Focus on: Smart Maintenance 12 | Plant & Works Engineering www.pwemag.co.uk October/November 2025 The manufacturing sector is entering a new era of digital transformation, one where automation, robotics, and datadriven production processes are deeply embedded in everyday operations. This transformation has created extraordinary opportunities for efficiency and growth. It has also exposed manufacturing environments to a surge of new cybersecurity risks. Increasingly, cybercriminals are targeting operational technology (OT) and exploiting vulnerabilities in interconnected supply chains. Ransomware, in particular, has emerged as one of the most disruptive threats, capable of halting production lines and, supply networks, while inflicting lasting reputational damage. As factories embrace digital maintenance and data-driven operations, security is becoming a core part of reliability. In response, policymakers are introducing tougher cybersecurity regulations. In the United Kingdom, the Cyber Security and Resilience Bill will strengthen existing frameworks and expand the scope of security obligations for organisations. Meanwhile, in the European Union, the NIS2 Directive, which came into effect in October 2024, significantly raises the bar for compliance across critical sectors, including manufacturing. Together, these regulations mark a turning point in how governments expect industry to defend itself against escalating cyber threats. The UK Cyber Security & Resilience Bill The UK Cyber Security and Resilience Bill represents the next step in the country’s strategy to strengthen its national cyber defences. Building on the earlier Network and Information Systems (NIS) Regulations 2018, the new Bill will modernise requirements in several ways. First, the Bill expands the scope of sectors and organisations that fall under its remit. Advanced manufacturing and critical suppliers of components or services are now considered part of the UK’s critical national infrastructure. This reflects the government’s recognition that a single disruption in the manufacturing supply chain can ripple across the economy. Second, the Bill emphasises resilience as much as protection. Organisations will be expected to show not only that they can prevent attacks, but also that they have effective continuity measures in place to recover from them. This shift acknowledges the reality that cyber incidents are inevitable, and what matters is how quickly and effectively a business can respond. Finally, the Bill gives regulators stronger supervisory powers. Authorities will be able to carry out audits, request compliance evidence, and impose stricter penalties for organizations that fail to meet requirements. For manufacturers, this means increased scrutiny of both IT and OT environments, along with supply chain practices. Operational Technology under the microscope One of the most important aspects of the UK Bill is its focus on operational technology. In many factories, production equipment is still controlled by legacy systems that were not originally designed with cybersecurity in mind. These systems often cannot be patched easily and may be exposed through remote access or poorly segmented networks. For maintenance teams, securing these systems is essential to ensuring continuous, predictable performance. The Bill requires manufacturers to adopt a risk-based approach to OT security. This includes conducting regular risk assessments, monitoring for threats, and ensuring that incident response plans are tailored to production environments. For example, if a ransomware attack locks up control systems, organisations must be able to isolate affected areas quickly, switch to backups, and restore production without compromising safety. The EU’s NIS2 Directive The European Union’s NIS2 Directive goes further still, creating one of the most comprehensive cybersecurity frameworks in the world. Effective from October 2024, NIS2 applies to both “essential” and “important” entities, with manufacturing explicitly listed as a critical sector. Sub-sectors range from electronics and automotive to chemicals and machinery production, meaning that most medium and large manufacturers in the EU will fall within scope. Smart maintenance starts with cybersecurity Smart maintenance depends on connected systems, automation, and remote access but these same technologies also increase exposure to cyber threats. With the UK’s Cyber Security and Resilience Bill and the EU’s NIS2 Directive setting higher expectations, manufacturers must embed cybersecurity into every layer of maintenance to protect uptime and resilience. Maria Else, Senior Global Product Manager Industrial Network & Cybersecurity at Rockwell Automation explains further.
Focus on: Smart Maintenance Maintenance Matters October/November 2025 www.pwemag.co.uk Plant & Works Engineering | 13 NIS2 sets out a minimum set of cybersecurity measures that all in-scope organizations must implement. These include asset management, incident handling, business continuity, supply chain security, and the use of encryption and multi-factor authentication. Importantly, supply chain security is no longer optional. Companies must actively assess the cybersecurity practices of their suppliers, monitor for vulnerabilities, and document mitigation measures. Reporting obligations are also far stricter than before. Organisations must provide an early warning of a severe incident within 24 hours, submit a more detailed incident notification within 72 hours, and deliver a final report within one month. Failure to comply can result in severe fines: up to 2% of global turnover or €10 million for essential entities. Beyond financial penalties, senior management can also be held personally liable for failures to comply with the directive. Why OT security Is a priority For manufacturers, one of the most significant changes under NIS2 is the explicit inclusion of OT systems. These systems manage essential industrial functions, from assembly lines to energy management. Unlike IT systems, OT environments are often designed for reliability and safety rather than cybersecurity. Many run on outdated software, making them easy targets for attackers. The European Union Agency for Cybersecurity (ENISA) has repeatedly warned that ransomware remains the most serious threat to industrial operations. Its reports show that attackers are increasingly exploiting unpatched OT systems and moving laterally from IT to OT networks once they gain a foothold. By bringing OT into the scope of NIS2, regulators are making clear that manufacturers can no longer treat it as separate or immune from cyberattacks. Comparing the UK and EU Approaches While the UK Bill and NIS2 share many similarities, there are important differences. Both emphasise accountability at the executive level, but the EU goes further by making senior managers personally liable for compliance failures. Both require organisations to manage supply chain risks, but NIS2 mandates specific processes and coordinated risk assessments. The UK framework is likely to be more flexible, giving regulators discretion in how requirements are applied across different industries. The EU framework, in contrast, is more prescriptive, aiming to harmonize cybersecurity standards across all member states. For manufacturers operating in both regions, this means navigating overlapping but distinct obligations, which will require careful coordination of compliance strategies. The Ransomware challenge Ransomware is a unifying theme across both sets of regulations. Manufacturing is particularly vulnerable because downtime translates directly into financial loss. Attackers know that production stoppages create pressure to pay ransoms quickly, making manufacturers attractive targets. Both the UK Bill and NIS2 encourage organisations to adopt a defence-in-depth approach to ransomware resilience. This includes network segmentation to separate IT and OT, secure remote access controls for suppliers, regular patching where possible, and robust backup and recovery strategies. Organisations must also test these measures in realistic scenarios, ensuring they can respond quickly under pressure. Preparing for compliance For manufacturers, preparing for these regulations is not just about avoiding fines; it is about safeguarding business continuity. Specific Cybersecurity OT Policies and Procedures are a fundamental part of NIS2 and will define the organisations approach to securing the OT environment. The following steps are critical: Conduct a thorough inventory of IT and OT assets, identifying those critical to operations. Implement a Cyber Security Management System and establish a risk management strategy. Map supply chains and evaluate the cybersecurity maturity of key partners. Establish and test incident response procedures, ensuring OT scenarios are included. Invest in scalable OT security technologies, such as asset and vulnerability management, industrial intrusion detection and secure remote access tools. Provide regular cybersecurity training for staff at all levels, from engineers on the factory floor to executives in the boardroom. By taking these steps now, manufacturers can build resilience that meets regulatory requirements while also protecting their reputation, customer trust, and long-term competitiveness. The UK Cyber Security and Resilience Bill and the EU’s NIS2 Directive represent a significant shift in the cybersecurity landscape for manufacturers. Both frameworks underline the growing importance of protecting operational technology, managing supply chain risks, and building resilience against ransomware. The consequences of noncompliance are severe, but the potential benefits of compliance such as greater operational resilience, stronger customer trust, and reduced exposure to cyber threats are just as significant. For manufacturers, the message is clear. Cybersecurity is no longer a matter for the IT department alone. It is a board-level priority and a critical element of business resilience. At its core, cybersecurity is about more than protecting factories or supply chains—it is about safeguarding our everyday lives, ensuring the safety of workers, communities, and the essential services we all depend on. Those who act now to strengthen their defences will not only comply with new laws but also gain a competitive advantage in a digital-first industrial era. For further information please visit: https://www.rockwellautomation.com/engb.html
14 | Plant & Works Engineering www.pwemag.co.uk October/November 2025 Advertorial which makes the motor shaft wobble, or a shaft that has become misaligned with the load. It could also mean the mounting bolts are loose. Allowing a motor to run while vibrating will only accelerate the damage. The constant shaking can harm the bearings, damage the windings and loosen electrical connections — leading to much bigger problems. 4. The Motor Is Losing Its Accuracy You use servo motors for one primary reason — precision. A motor positioned incorrectly compromises your entire process. This accuracy concern often appears as drifting, where the motor stops just short of or just past its target position. You might also see jerking or lagging movements where it struggles to follow commands. This is a sign that its feedback device, the encoder, may be failing. A study on servo diagnostics highlights that erratic movement and positioning errors are frequently traced back to encoder or feedback problems. Addressing this proactively prevents the motor from losing control entirely, which could damage the machine or your product. 5. The Drive Trips or Shows Random Alarms Occasional glitches are almost never just glitches. If a servo repeatedly trips its breaker or shows intermittent fault codes, there’s an underlying issue. These alarms might be related to over-current, over-voltage or encoder faults. It can be tempting to simply reset the alarm and restart the machine, especially during a busy production run. However, these errors are your system’s built-in diagnostic. They could be warning you of failing cables, power supply instability or an electrical short in the motor windings. Investigating the root cause of these alarms is what proactive maintenance is all about. Where to Find the Best Value Repair Services for Servo Motors When one of these signs appears, the next step is finding a repair partner with a positive track record. U.S.-based Global Electronic Services is one such servo repair specialist that caters to international clients, including those in the U.K. It offers a two-year service warranty and a free 24- to 48-hour rush service — critical for minimising downtime. The high cost of failure underscores the need for a reliable partner. The world’s largest companies can lose a significant percentage of their annual revenue to unplanned downtime, with faulty equipment being a primary culprit. This reinforces the value of using an expert that can provide a fast, reliable refurbishment. Keep Your Operations in Motion A servo motor failure is always disruptive, but you change the dynamic by training your team to spot the signs proactively. Listening for noise, feeling for heat and watching for inaccuracy are simple checks that protect your most critical asset Global Electronic Services sales@gesrepair.com https://gesrepair.com/ 5 Telltale Signs Your Servo Motor Needs Proactive Attention You can count on servo motors to be precise and powerful on your production lines. However, when one of them breaks down, it can bring operations to a halt and cost you time and money. The key is to catch problems before they lead to a full breakdown. Looking for the best servo motor repair services is smart, but it’s much better to prevent failure in the first place. Analysing your equipment for five early warnings is the most effective way to manage maintenance proactively. 1. You Hear Squealing, Grinding or Whining Your facility is likely noisy, but your maintenance teams should be familiar with the normal machine sounds. When a servo motor begins to produce new, unusual noises, it’s a clear mechanical warning. High-pitched squealing or whining often points to failing bearings or a brake issue. A rough grinding sound can indicate worn-out bearings, an internal misalignment or contamination within the motor housing. These sounds are the direct result of friction and components struggling. Investigating the source of the noise lets you schedule a repair before the component seizes completely. 2. The Motor Housing Is Too Hot Heat is the primary energy source of any mechanical or electronic component. Servo motors do heat up during regular operations, but a unit that’s too hot to the touch is a red flag. There are a number of reasons why this can happen. The motor might be overloaded and drawing too much current. It could also be a sign of poor ventilation, with debris and dust blocking airflow. A spike in temperature can also be caused by pieces that are broken or worn out and produce more friction. This thermal stress can degrade insulation and lead to catastrophic failure. A thermal camera can assist you in finding a motor that’s running hotter than its counterparts during regular checks. 3 You Notice Wobbling or Excessive Shaking Too much vibration, like strange noises, is a physical sign of an internal problem. A properly mounted servo motor should operate smoothly. When you notice new or increasing vibration, it is a warning that something is out of place. Common causes include bearing wear,
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