NEWS | FEATURES | PRODUCTS | CASE STUDIES www.pwemag.co.uk @PWEmagazine1 Why traditional cyber defences are no longer enough Inside this issue 14 > Making the business case for condition monitoring 18 > The unsung filtration heroes of reliable compressed air 20 > Why lifecycle thinking is key to energy-efficient pumping systems page 34 @plant-&-works-engineering PWE Plant & Works Engineering Since 1981 October/November 2026 | Issue 495
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The real question for Britain’s manufacturing and engineering sectors is whether the Government can create the conditions needed for sustained industrial growth. A defining test for Burnham and Healey The Autumn Budget represents an important early test for Prime Minister Andy Burnham and the Chancellor, John Healey. Beyond the political headlines and inevitable debate over taxation and spending, the real question for Britain’s manufacturing and engineering sectors is whether the Government can create the conditions needed for sustained industrial growth. For a Prime Minister who has placed considerable emphasis on revitalising communities and strengthening the economy beyond Westminster, the expectations are understandably high. But turning political ambition into economic reality is rarely straightforward. British manufacturers continue to face significant challenges. Some of the highest energy costs in Europe, rising employment expenses, persistent skills shortages and uncertainty over future investment are placing considerable pressure on businesses already competing in demanding global markets. At the same time, industry is being Editor’s Comment ‘ ’ encouraged to embrace automation, digitalisation, artificial intelligence and decarbonisation. These are essential elements of a competitive industrial future, but they all require investment, skilled people and, perhaps most importantly, business confidence. And confidence is difficult to build when the costs of operating remain unpredictable. For the plant engineers, maintenance professionals and manufacturing managers who make up much of this magazine’s readership, the challenges are particularly tangible. Improving reliability, extending asset life, reducing downtime and increasing energy efficiency are everyday priorities, often delivered against increasingly constrained budgets. Yet these activities rarely feature prominently in the national debate about economic growth. There is a tendency for industrial policy to focus on major new projects, emerging technologies and high-profile investment announcements. While these are undoubtedly important, the Government must not overlook the enormous economic value of maintaining and modernising the industrial infrastructure Britain already possesses. Investment in existing plant and machinery, improved maintenance practices, energyefficient equipment and workforce development can deliver substantial productivity gains without the need for entirely new facilities. The same applies to the transition towards a lower-carbon economy. Industry recognises the importance of reducing emissions, but businesses need a practical and affordable route towards achieving those ambitions without sacrificing international competitiveness. For Burnham and Healey, the challenge is therefore about more than balancing the nation’s books. It is about demonstrating that the Government understands what businesses need to invest with confidence, improve productivity and create skilled employment. That means greater policy consistency, competitive energy costs, meaningful support for skills development and a long-term approach to industrial investment. Of course, no single Budget can resolve every challenge facing British industry. Nor should businesses expect government alone to provide all the answers. But economic policy has a significant influence on the willingness of companies to commit capital, embrace innovation and plan for the future. Ultimately, the success of the Government’s economic approach will be measured not simply by the announcements made at Westminster, but by the investment decisions taken in factories, workshops and engineering departments across the country. For Burnham and Healey, the real test is whether their ambitions for growth translate into a stronger, more productive and more competitive industrial Britain. October/November 2026 www.pwemag.co.uk Plant & Works Engineering | 03
AWARDS OPEN TO EVERYONE We’re celebrating the very best in the electro-mechanical service and repair industry — and every company is invited to enter. Big or small. First-time entrant or seasoned contender. If you, your company, a project, or a product/service offering is making an impact, we want to hear your story. The 2026 AEMT Awards Join the industry celebration: Thursday 19th November 2026 Doubletree by Hilton, Coventry 30th Sep Judges Convene 20th Apr Nominations Open 11th Sep Nominations Close 19th Nov Winners Announced 9th Oct Finalists Announced Entry is free of charge and multiple entries are not only allowed, but encouraged! For more information and to submit your entries, please visit: AEMTAWARDS.COM Enter one (or more) of the 10 categories: • Product of the Year • Project of the Year • Supplier of the Year • Rising Star • Diversity in Engineering • Service Centre of the Year – Large • Service Centre of the Year – Small • Electro-Mechanical Champion of the Year • Contribution to Skills and Training • Sustainable Organisation of the Year Sponsors: More sponsorship opportunities available!
October/November 2026 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 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 2026, 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 30 12 24 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 - INCORPORATING PROBLEM SOLVER 12 Focus on: Smart Maintenance/ Condition Monitoring Beth Ragdale explains why real-time analytics is becoming one of the most effective tools for improving energy efficiency and reducing operational costs. PROCESS, CONTROLS, & PLANT 18 Focus on: Compressed Air/ Pumps & Valves Pure, reliable compressed air and gases help to keep industrial operations running smoothly. In compressed air and gas systems, including hybrid applications like airdriven hydraulic pumps and air-over-oil systems that rely on clean plant air to generate hydraulic force, filtration is an active part of process reliability. ENERGY & ENVIRONMENTAL MANAGEMENT 24 Focus on: Boilers, Burners & Controls/ Cooling For industrial operators, burner performance is about far more than simply producing heat. Incorrect commissioning, poor combustion set-up or ineffective fault diagnosis can affect efficiency, emissions, equipment reliability and, ultimately, production continuity. HANDLING & SAFETY MATTERS 30 Focus on: Handling & Storage As more businesses adopt electric forklifts, choosing the right type of electric lift truck is becoming just as important as choosing an electric power source in the first place. PWE reports. SPECIAL FOCUS INDUSTRIAL SECURITY 34 ADVANCED ENGINEERING 36 WATER MANAGEMENT 38 PRODUCTS & SERVICES DIRECTORY 42
News 6 | Plant & Works Engineering www.pwemag.co.uk October/November 2026 The Government must put “some flesh on the bones of the buzzwords” if its ambitions for reindustrialisation and growth in every postcode are to succeed where levelling up and building back better fell short, according to manufacturers. Ahead of the Autumn Budget, Make UK has urged the Chancellor to focus on reducing the cost pressures holding manufacturers back from hiring, investing and growing, warning that ambitions for reindustrialisation will fail unless businesses are first given room to breathe. The organisation also stressed that the Government’s commitment to reindustrialisation must build on the certainty provided by the recently published Industrial Strategy. Manufacturers need long-term stability and confidence to invest, alongside practical measures that improve competitiveness today. The organisation is calling on the Government to: Address the UK‘s uncompetitive industrial energy costs by moving policy levies from electricity bills into general taxation. Reduce the cost of employing people by reversing the cut to the Employer National Insurance threshold and extending NIC reliefs to all workers under 25. Keep National Living Wage increases sustainable by limiting rises to 3.7% and delaying the extension of the National Living Wage to 18year-olds until the impact on youth employment can be properly assessed. Take a more proportionate approach to the Employment Rights Act, particularly around guaranteed hours and implementation timescales, to avoid making it harder for manufacturers to recruit. Introduce 100% transitional business rates relief for manufacturers in 2026/27, giving firms breathing space from recent increases in rates bills. The proposals are backed by Make UK‘s latest survey of manufacturers, which found that 47% believe cutting industrial energy costs should be the Government’s top manufacturing priority, followed by 37% who want lower Employers’ National Insurance costs, 32% who want employment rules made simpler and less costly for businesses and 31% who want business rates reduced. The research also highlights growing concern about employment regulation. Just 11% of manufacturers believe the Employment Rights Act should continue as planned, while 36% want the next stages paused and reviewed, 22% want the most burdensome measures reversed and a further 11% want implementation delayed to give businesses more time to prepare. While 56% of manufacturers say they feel positive about the Government’s ambition to reindustrialise the economy, they say success will ultimately be judged on outcomes. Asked what would show Government was delivering for manufacturing in a year’s time, 43% chose lower operating costs, 36% more competitive energy prices, 35% more manufacturers increasing investment in the UK and 29% more manufacturing jobs being created. Stephen Phipson CBE, Chief Executive of Make UK, commented: “Governments are good at promising economic resets but delivering them is much harder. If reindustrialisation and growth in every postcode are to succeed where levelling up and building back better didn’t, it’s time to put some flesh on the bones of the buzzwords. “The Autumn Budget is the first real test of the Government’s reindustrialisation agenda. The Chancellor needs to show, through action not words, what the Government’s promises actually mean. “For UK manufacturers, that means making decisions right now to ease the burdens they face. If the Government wants our members to stay afloat, the first step is to take some of the weight off their shoulders. “Manufacturers don’t need flashy new schemes and announcements. They need Government to remove the barriers that stop them from hiring, investing and growing.” Reindustrialisation must not become the next levelling up, manufacturers warn Chancellor visits MTC to outline growth ambitions The Manufacturing Technology Centre (MTC) recently welcomed John Healey MP, Chancellor of the Exchequer, to its Coventry headquarters, where he set out his vision for driving economic growth across the UK. Speaking from MTC’s new Robot Experience Centre, the Chancellor outlined plans to support growth through investment, innovation and skills development, alongside greater devolution, highlighting how removing obstacles in these areas will strengthen the UK’s economy. The Chancellor was joined by the West Midlands Mayor, Richard Parker, the Rt Hon Jonathan Reynolds, Secretary of State for Business, Innovation, Science and Trade, and the HM Treasury Ministerial Team. The visit provided an excellent opportunity to showcase the expertise, capabilities, and innovation that make MTC a national asset for advanced manufacturing. Equally important was the focus on skills and talent. The Chancellor spent time speaking with apprentices based at MTC Training’s centre at Ansty Park and touring our state-of-the-art training facilities. Opening his speech, John Healey, Chancellor of the Exchequer, said: “The MTC is an organisation at the very heart of Advanced Manufacturing – and advanced manufacturing is one of our eight Industrial Strategy growth sectors as a government… [MTC] was established to unlock the potential of the UK industry, with practical, leading edge manufacturing with innovation. What better place therefore, for me to speak with you about this government’s determination, our determination for growth, our belief for Britain’s future.” In his speech, the Chancellor went on to emphasise the partnership between government, business and academia and the importance of investment, innovation and skills as drivers of
News October/November 2026 www.pwemag.co.uk Plant & Works Engineering | 07 economic growth. On innovation, the Chancellor commented: “The UK is the third in the world for innovation. Our record is extraordinary. I mean, pause and look around in the MTC. “Our UK formula works: local leaders working with world-class universities, investors, local businesses have created clusters of innovation across the UK… As a result, we are world leaders in frontier technologies – in quantum, in nuclear fusion, in AI, in advanced manufacturing. “But too often, ideas born here in Britain have to go elsewhere to find the capital they need to grow– meaning that the jobs, the benefits and the intellectual property go elsewhere… “Over the coming months I want to go further, working with more departments to earmark dedicated funds to Back British innovation.” SPS 2026 brings industrial AI and software defined automation into practice Industrial AI, software-defined production and advanced communications will be among the technologies taking centre stage when the international automation industry gathers in Nuremberg for SPS – Smart Production Solutions 2026. Around 1175 exhibitors from 40 countries are expected to showcase industrial automation technologies at SPS – Smart Production Solutions, taking place at the Nuremberg exhibition centre from 24–26 November 2026. Spread across 15 halls, the exhibition will cover the industrial automation spectrum, from sensors, drive technology and industrial communications to software and integrated automation solutions for the digital factory. Alongside new products, the event will focus on a question becoming increasingly important for manufacturers and machine builders: how emerging technologies can move beyond demonstration projects and deliver measurable benefits in industrial environments. Industrial AI, software-defined production architectures, IT/OT integration, 5G industrial communications and cybersecurity are consequently expected to feature prominently across the exhibition and its technical programme. SPS also continues to attract an international audience of end users and decision-makers. More than 500 visitors from the UK attended the 2025 event. “For many years, the SPS has been the place where technological developments are showcased before they become widespread throughout the industry,” said Sylke Schulz-Metzner, Vice President SPS at Mesago Messe Frankfurt. “The expo not only highlights trends but also allows visitors to experience them firsthand. It facilitates dialog among suppliers, users, and innovation partners.” Information on tickets, the exhibition programme, exhibitor directory and visitor services is available at: https://sps.mesago.com/nuernberg/en/expo.html Girls lead the way in engineering jobs of the future Girls are rewriting the rules of engineering, with new research revealing they are leading the charge into some of the profession’s fastest growing and most high-tech careers. Rather than following traditional engineering pathways, they are increasingly drawn to fields shaping the future, including biomedical engineering, biotechnology, artificial intelligence and healthcare technologies. A major study by the Institution of Mechanical Engineers (IMechE) and careers platform Unifrog, The Future is Engineering: What Young People Really Think, has found that while boys still dominate engineering overall, the traditional gender divide has disappeared in biomedical engineering, suggesting girls are increasingly choosing engineering careers that combine technology, healthcare and innovation. The report also busts one of the biggest myths surrounding the profession. Contrary to perceptions that engineering struggles to attract young people, it has become one of the UK’s most popular subjects for students planning their future, ranking third out of 21 university subject areas researched. Overall, boys remain more likely to shortlist engineering degrees, at 14% compared with 4% of girls. However, students interested in
News 08 | Plant & Works Engineering www.pwemag.co.uk October/November 2026 Shaping manufacturing’s future: why we need to talk about what comes next UK manufacturing is at an important moment. The sector is facing significant challenges, but alongside them are opportunities that could reshape the future of British industry. From AI and advanced technologies to the transition to a lowercarbon energy system, changing global trade patterns and growing demand for defence and infrastructure, the direction of travel is clear. The question is whether we can move quickly enough to capture these opportunities, and whether the UK has the right conditions, skills and investment to do so. That is why bringing the manufacturing community together matters. Businesses are navigating rising costs, skills shortages, rapid technological change and an increasingly uncertain global environment. At the same time, decisions on industrial strategy, energy, trade, skills and regulation will have consequences for manufacturers for years to come. We need a conversation that connects all of these issues. That is the thinking behind Make UK’s National Manufacturing Conference 2027, taking place at the QEII Centre in London on 23 February. It will bring together manufacturers, policymakers and industry leaders to look beyond the immediate pressures facing businesses and focus on what comes next. The agenda reflects the breadth of the opportunities and challenges ahead: from technology adoption and AI; energy and workforce resilience; to trade, defence and the UK’s industrial capacity. But the conference is not simply about hearing from policymakers and industry leaders. It is an opportunity for manufacturers themselves to shape the conversation. Manufacturing cannot afford to be a spectator in the decisions that will define its future. We need to be clear about the support businesses need, while also being ambitious about what the sector can deliver for the UK economy. The next few years could be transformative for British manufacturing. Whether that transformation strengthens our industrial base, creates highvalue jobs and attracts investment will depend on the choices we make now. Our National Manufacturing Conference is about bringing the sector together to debate these questions, challenge assumptions and help shape what comes next. I hope to see the manufacturing community there. Stephen Phipson CBE Chief Executive, Make UK * Find out more and book your place: makeuk.org/nationalmanufacturing-conference By MAKE UK chief executive, Stephen Phipson MAKE uk - the manufacturers’ organisation monthly news comment engineering are more likely to see themselves as strong problemsolvers and confident with numeracy, at 68% and 47% respectively, compared with 59% and 35% of their peers. Engineering-minded students are also more likely to engage with employers, attend careers events and visit universities, with 37% doing so compared with 24% of non-engineering students. And they are significantly less interested in fame or prestige than students studying different subjects, at 12% compared with nearly a quarter (20%) of other students. Instead, they place greater value on practical experience, employer engagement and understanding their future career opportunities. Matthew Rooney, Head of Engineering Policy and Impact at the Institution of Mechanical Engineers, said: “Engineering is changing, and young people are changing with it. The stereotype that engineering is only about engines, factories and hard hats is disappearing. “Today’s engineers are designing life-saving medical devices, developing artificial intelligence, transforming healthcare and tackling some of society’s biggest challenges. It’s encouraging to see more girls recognising that engineering offers exciting careers where they can make a real difference. “While there is still much more to do to close the overall gender gap, these findings show the future of engineering is becoming broader, more diverse and more appealing than ever before.” The report highlights biomedical engineering as one of the fastestgrowing disciplines, driven by an ageing population, healthcare innovation and advances in medical tchnology – creating opportunities for more women to help tackle engineering’s wider skills gap. Interest in engineering is consistent across socioeconomic backgrounds, challenging the idea that it mainly appeals to particular groups or areas. However, traditional disciplines such as civil engineering remain less popular, despite their vital role in housing, infrastructure, climate resilience and Net Zero, creating a future skills risk. Based on anonymised Unifrog data from thousands of 14 to 16year-olds, the report reveals not just what subjects interest young people, but how they approach careers – with aspiring engineers actively seeking information, employer engagement and real-world experience.
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10 | Plant & Works Engineering www.pwemag.co.uk October/November 2026 Insight When a pneumatic cylinder begins moving slowly, hesitating, stopping short or producing inconsistent cycle times, the cylinder is often blamed first. Replacing seals or installing a new actuator may appear to solve the problem, but the improvement can be temporary if the real fault is elsewhere in the circuit. A cylinder is the final device in a chain that includes the compressor, receiver, distribution piping, filter and regulator, directional valve, tubing, fittings, flow controls and exhaust silencers. It also works against a mechanical load that may be misaligned, binding or changing from cycle to cycle. Effective troubleshooting therefore starts with the symptom and operating Before you replace the pneumatic cylinder When pneumatic cylinder performance becomes slow or inconsistent, replacing the actuator may treat the symptom rather than the cause. A systematic investigation of pressure, airflow, valves, exhausts, air quality and mechanical loading can reveal where the real problem lies and help prevent unnecessary component changes and repeat failures. Palak Sheth* reports. conditions, not with an assumption about the failed component. Define the symptom before changing anything Begin by recording exactly when the problem occurs. A cylinder that is slow in both directions suggests a common supply restriction, low available flow, valve problem or mechanical drag. Slow extension with normal retraction points toward the cap-end supply path, the rodend exhaust path, a direction-specific flow control or the load during extension. A machine that performs normally without load but slows in production may have insufficient force margin, dynamic pressure loss or external binding. Timing also matters. If performance deteriorates only when other air consumers operate, inspect the shared branch and local distribution capacity. If motion is erratic after a long idle period but stabilises after several cycles, moisture, contamination, seal stiction or lubrication conditions may be involved. A concise symptom record prevents the investigation from becoming a series of unrelated component swaps. Measure pressure where the work occurs A regulator gauge can show acceptable pressure while the machine is idle and still hide a serious loss during movement. Pressure should be checked near the actuator while the cylinder is travelling under its normal load. Record the starting pressure, the lowest pressure reached during the stroke and whether the drop changes when neighbouring equipment cycles. technician measures pressure close to the pneumatic cylinder during a controlled operating test. Dynamic readings at the actuator can reveal pressure losses that are not visible at the compressor or regulator. Image credit: AI-generated.
Insight October/November 2026 www.pwemag.co.uk Plant & Works Engineering | 11 The Compressed Air and Gas Institute explains in its pressure-drop guidance that losses accumulate through piping, filters, dryers, fittings and other restrictions. The British Compressed Air Society also recommends examining compressed-air distribution as a complete system. A large difference between upstream and actuator pressure during motion can indicate undersized tubing, excessive length, restrictive fittings, a blocked filter or inadequate branch capacity. Raising plant pressure may conceal the symptom while increasing energy use and stress elsewhere, so it should not replace diagnosis. Compare extension and retraction A double-acting cylinder does not behave identically in both directions. The effective piston area changes because of the rod, and each stroke uses a different valve passage, tube and exhaust route. Compare extension and retraction times under the same controlled conditions. Then check the supply and exhaust sides associated with the slower direction. Meter-out flow controls are commonly used to stabilise speed, but a misadjusted or contaminated control can restrict movement. An exhaust silencer can also load with oil, dust or water and create backpressure. A practical pneumatic circuit troubleshooting checklist identifies tubing size, speed controllers, load variation and supply conditions among the points to verify when cylinder speed is unstable. Any adjustment should be documented so the original setting is not lost. Follow the entire flow path Trace air in sequence from the local shut-off and regulator to the filter, valve, fittings, tubing, flow controls and cylinder ports. Look for kinked tube, damaged push-in fittings, long runs, small internal diameters and sharp changes in direction. Confirm that the directional valve is receiving a reliable pilot signal and shifting fully. A valve can energise electrically without providing full pneumatic flow if its spool is contaminated or mechanically restricted. Inspect the exhaust path with the same care as the supply path. A plugged silencer or restricted exhaust fitting can slow the opposite cylinder stroke and may be missed when attention stays on inlet pressure. Before removing components, isolate and depressurise the system according to the machine manufacturer’s instructions and the site’s safety procedure. Live diagnostic tests should be planned and performed by qualified personnel under controlled conditions. Check air quality and idle-time behaviour Compressed air can carry particles, water and oil. ISO 8573-1 defines purity classes for these contaminants, but the appropriate class depends on the application and equipment requirements. A filter bowl that appears acceptable at a glance does not prove that the air reaching a valve is dry or clean under all operating conditions. Guidance on compressed-air contamination describes how dirt, water and oil can affect pneumatic components. Check drains, filter condition, dryer performance and evidence of contamination at silencers or valve exhausts. If erratic motion appears after shutdowns, record ambient conditions and drain findings rather than immediately attributing the behaviour to worn cylinder seals. Separate pneumatic faults from mechanical resistance A sound pneumatic circuit cannot compensate for a binding mechanism. Inspect cylinder mounts, rod alignment, guides, linkages, stops and the driven load. Side loading can damage seals and bearings while also creating inconsistent motion. Cushion settings that are too restrictive can resemble a flow problem near the end of a stroke. Debris, thermal expansion or a changed workpiece can also increase resistance. Where the machine design and risk assessment allow it, compare actuator behaviour with the load safely removed or decoupled. If speed and repeatability return, the fault may be outside the cylinder. If the problem remains, continue checking pressure, flow and the actuator itself. Never disconnect a load unless stored energy, gravity and unexpected movement have been controlled. Change one condition at a time Good troubleshooting depends on preserving context. Record the asset, operating load, upstream and local pressure, extension and retraction time, valve state, flow-control settings, air-quality observations, nearby demand and the outcome of each change. Digital asset inspection software can help keep observations, photographs and corrective actions connected to the same equipment history. Likewise, well-designed manufacturing software can preserve process conditions and verification results instead of reducing the event to a closed work order. Change only one variable at a time whenever practical. Cleaning a silencer, adjusting a flow control and replacing a valve simultaneously may restore motion, but it prevents the team from learning which action mattered. After a correction, verify several cycles under normal load and during realistic plant demand. A single successful stroke is not proof that the root cause has been removed. Replace the cylinder only when the evidence points there Cylinder wear remains a legitimate failure mode. Internal leakage, damaged seals, scored surfaces, bent rods and worn bearings can all reduce force or create erratic movement. The point is not to exclude the cylinder, but to reach that conclusion after the circuit and mechanical load have been checked. A symptom-led process prevents unnecessary replacement and produces a more useful maintenance record. Measure pressure at the point of use, compare both directions, inspect supply and exhaust restrictions, assess air quality, check alignment and verify the repair under real operating conditions. When the full path is examined, technicians are more likely to correct the cause of inconsistent actuation instead of replacing the component at the end of it. *Palak Sheth is a Digital Marketing Specialist at Konverge Digital Solutions, She develops technical and educational content about inspection management, asset reliability, preventive maintenance, industrial troubleshooting and the practical use of operational data. A pneumatic circuit inspection should extend beyond the cylinder to the valve manifold, airpreparation components, tubing, flow controls and exhaust silencers. Restrictions or contamination in these components can produce unstable actuator speed. Image credit: AI-generated.
Maintenance Matters Focus on: Smart Maintenance 12 | Plant & Works Engineering www.pwemag.co.uk October/November 2026 Rising energy costs mean manufacturers are looking more closely than ever at how their factories consume power and where unnecessary energy is being lost. However, while most businesses know how much energy an entire site consumes, far fewer understand where that energy is being used, or wasted, at machine level. The UK Government has announced the British Industrial Competitiveness Scheme, which will help to cut energy bills by up to 25 per cent for more than 10,000 manufacturers in early 2027. This will be welcomed by the companies, but it shows how serious the energy issues are at the moment. Without visibility into individual assets and processes, manufacturers can spend thousands on electricity without knowing which machines are operating inefficiently, where maintenance issues are emerging or whether equipment is consuming power when it is producing nothing at all. The biggest opportunity lies in treating energy as another source of operational data, rather than simply another utility bill. If you know how much energy a machine should use to produce a part, any deviation tells you something. It could be an overworked motor, a compressed air leak, a vacuum pump running continuously or simply a machine that’s still consuming power when it should be idle. This shift from measuring total energy consumption to analysing energy at machine level is changing how manufacturers approach both efficiency and maintenance. Looking beyond the electricity meter Real-time analytics allows manufacturers to build a performance profile for every machine. Instead of simply recording how much electricity a factory consumes over a day or month, engineers can compare energy use against production output, operating conditions and machine health. If a production line continues to draw significant power during downtime, it may indicate that equipment is not entering standby mode correctly, or at all. On a packaging line, for example, infeed conveyors or rotary tables may continue to run when then machine is blocked further down the line. Equally, a motor that suddenly requires more power than usual may be signalling the early stages of mechanical wear. The same principle extends beyond electrical consumption. Modern automation platforms can combine energy data with other signals from the machine, such as torque speed, vibration, temperature, valve states, flow rate, environmental conditions and machine state to provide a far richer picture of machine performance. For example, increasing vibration alongside higher energy consumption often points towards equipment operating outside its normal condition. Rather than waiting for a failure, manufacturers can identify these trends early and investigate before production is affected. Compressed air is another example. Often described as one of the most expensive factors in manufacturing, even small leaks can waste significant amounts of energy. By monitoring pressure, flow and machine state in real time, manufacturers can detect changes that suggest leaks or air being supplied during idle periods , reducing both energy use and operating costs. Whole factory efficiency Energy optimisation does not stop at the production line. While manufacturers often focus on improving machine efficiency, building management can have an equally significant impact. Heating production areas while loading doors remain open, lighting unused areas, running extraction when the process is inactive, or failing to recover excess heat all contribute to unnecessary energy consumption. Modern automation systems increasingly allow manufacturers to combine machine data with building management information. Instead of treating production equipment and facilities as separate systems, they become part of a single energy strategy. Data creates smarter maintenance Energy analytics also supports predictive maintenance, one of the fastest-growing applications of industrial data. For manufacturers producing high-volume consumer goods, even short periods of downtime can be extremely expensive. Rather than reacting after equipment fails, predictive Why energy analytics matter Beth Ragdale, software manager at Beckhoff UK, explains why real-time analytics is becoming one of the most effective tools for improving energy efficiency and reducing operational costs.
Focus on: Smart Maintenance Maintenance Matters maintenance uses operational data to identify developing problems before they stop production. Engineers can compare how a machine behaves over time. A drive that needs more current for the same movement, a gearbox that is running hotter than normal, or a fan that shows increasing vibration can all suggest that equipment is beginning to deteriorate. Instead of discovering a worn bearing after a breakdown, manufacturers can spot gradual changes in performance, schedule maintenance during planned shutdowns and avoid unexpected production losses altogether. The result is not only greater reliability but also improved energy efficiency, as machines operating within their intended parameters typically consume less power than poorly performing equipment. AI turns data into decisions The challenge for many manufacturers is no longer collecting data. Modern factories generate enormous volumes of information every second. Now, it’s about how to make sense of it. Artificial intelligence is increasingly becoming the link between raw industrial data and practical decision-making. Rather than engineers manually reviewing thousands of measurements, machine learning algorithms can identify patterns across energy use, compressed air demand, temperatures, vibration, motion profiles and production performance. Those insights help manufacturers understand relationships that would otherwise remain hidden and create increasingly accurate predictions of future performance. Looking ahead, manufacturers will move towards creating a digital profile for every machine. By combining operational history with live analytics, each asset will effectively develop its own performance passport, allowing operators to understand exactly how it should run for maximum efficiency, product quality and minimum energy consumption. Visibility drives efficiency While sustainability targets and environmental reporting continue to influence investment, commercial pressures remain the primary driver for many manufacturers. Rising energy prices have made efficiency impossible to ignore. The companies that gain the greatest advantage will not necessarily be those investing in entirely new equipment. Instead, they will be those extracting more value from the machines they already have by understanding how they perform in real time. Energy analytics provides that visibility. Once manufacturers know where energy is being used, why consumption changes and how operational decisions affect efficiency, they can make improvements that reduce costs, improve reliability and support long-term sustainability. As manufacturers continue to balance rising energy costs with productivity and sustainability targets, data will become one of their most valuable assets. By combining realtime analytics with intelligent automation, manufacturers can uncover hidden inefficiencies, make better operational decisions and reduce energy consumption without compromising output. For further information please visit: www.beckhoff.com Turck Banner Ltd. Blenheim House, Blenheim Court, Wickford, Essex SS11 8YT Tel: 01268 578888 wireless@turckbanner.co.uk Wireless Vibration & Temperature Monitoring As simple as your check engine light Distribute Connected data solutions • Data is pulled from the controller via cellular or Ethernet and Stored in a SCADA or Cloud Platform Alert and Consumption Consume the data via Dashboards, alerts and long term analysis • Early detection of any increase allows for planned, preventative maintenance Measure & Collect Wireless Vibration, Temperature & Current Monitoring • IP67 & IP69K Sensors • Sensors Powered by batteries Transmit IIOT Gateway/Controller Solution Kits • Sensors send data wirelessly to Gateway/Controller • Machine Learning Algorithm
Maintenance Matters Focus on: Condition Monitoring 14 | Plant & Works Engineering www.pwemag.co.uk October/November 2026 The business case for condition monitoring is strongest when framed around financial impact rather than technology. Its value lies in reducing both the likelihood of failure and the severity of its consequences. In many cases, avoiding a single major failure is enough to recover the full cost of the monitoring system. A practical way to understand this value is through risk, which can be expressed as the product of consequence and likelihood. If a compressor failure results in £500,000 of combined production loss, labour and spare parts, and it occurs once every ten years, the annualised risk is £50,000. If the same failure occurs every two years, the annual risk increases to £250,000. When a condition monitoring system detects early signs of failure and allows corrective action before damage occurs, that risk is either reduced or eliminated. The resulting financial benefit translates directly into ROI. Assessing ROI ROI is typically assessed using two measures: the payback period, which describes how quickly the investment is recovered, and the ROI ratio or percentage, which compares the benefits achieved over a defined period against the total cost of ownership. To produce a credible ROI calculation, both benefits and limitations of condition monitoring must be considered. Failure consequences vary significantly in severity and must be evaluated accordingly. At the lowest level are normal losses, which include production losses and maintenance costs during planned shutdowns. More severe are probable maximum losses, such as major repairs or full machine replacement combined with extended downtime. At the extreme are maximum possible losses, which may involve catastrophic equipment damage, safety or environmental incidents, fires, or prolonged business interruption. Condition monitoring delivers value by reducing the frequency of these events and by limiting their escalation. The largest contributor to ROI is typically reduced lost production. Preventing unplanned downtime improves availability, which often accounts for the majority of financial savings. For example, avoiding five hours of downtime on a machine producing £10,000 per hour results in £50,000 of preserved output. Alongside availability, labour savings are achieved through fewer emergency repairs, reduced overtime and more efficient maintenance planning. Maintenance records provide a reliable baseline for estimating these savings. Spare parts costs also decline as maintenance becomes more targeted. Early fault detection prevents secondary damage and avoids replacing components that are still in good condition. Energy consumption, while more difficult to quantify, can also be reduced. Machines operating in poor mechanical condition often consume more power, Making the business case for condition monitoring As production plants push existing assets harder and rely on machines that were once considered redundant, reliability has become a direct financial concern. With limited backup capacity, equipment failures now lead immediately to lost production, higher maintenance costs and increased operational risk. In this environment, condition monitoring is no longer justified primarily on technical grounds, but on its ability to deliver a measurable return on investment (ROI). James Donnelly* explains further.
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