Editorial

Following the successful installation two years ago of Landia Chopper Pumps and a Landia Aeration System, MSE Systems is set to install a further three units from Landia for one of the UK’s leading supplier of potatoes.

During an upgrade to the customer’s potato processing factory, Chesterfield-based MSE Systems found that the addition of a high-efficiency Dissolved Air Flotation (DAF) plant would improve the activated sludge process by reducing oxygen demand. To ensure that the plant could meet future needs, a new chemical addition system was introduced to remove suspended solids, free emulsified oils, grease and elevated residual phosphorus.

For odour control, an 11kW Landia AirJet system was installed to mix, aerate and control odours of screened potato effluent in a balance tank. In addition, two submersible Landia Chopper Pumps were brought in to pump screened potato effluent from a 4.5m deep pit (500m away), which included an additional 4m lift.

Andy Neal, Design Manager at MSE Systems, said: “Our challenge, which meant utilising a very small footprint between the existing plants, was to help our customer meet and maintain a stringent Environment Agency discharge consent, so that they remain fully compliant. The Landia AirJet and Chopper Pumps have proved very reliable and cost-effective, so it gave us the confidence to invest further in this equipment as the best, long-term solution.

He added: “For a new packing line, two submersible Landia Chopper Pumps will pump potato effluent, whilst a Landia Jet Mix system will mix organic sludge (dissolved solids 3-5%) in a 60m³ tank”.

MSE Systems ensured that the initial installation proceeded with the minimal amount of disruption, in order for their customer to reopen on schedule. Despite the tight time frame, the new wastewater treatment plant was delivered by MSE Systems ahead of deadline and within budget.

www.msesystems.co.uk

www.landia.co.uk

Following the successful installation two years ago of Landia Chopper Pumps and a Landia Aeration System, MSE Systems is set to install a further three units from Landia for one of the UK’s leading supplier of potatoes.

During an upgrade to the customer’s potato processing factory, Chesterfield-based MSE Systems found that the addition of a high-efficiency Dissolved Air Flotation (DAF) plant would improve the activated sludge process by reducing oxygen demand. To ensure that the plant could meet future needs, a new chemical addition system was introduced to remove suspended solids, free emulsified oils, grease and elevated residual phosphorus.

For odour control, an 11kW Landia AirJet system was installed to mix, aerate and control odours of screened potato effluent in a balance tank. In addition, two submersible Landia Chopper Pumps were brought in to pump screened potato effluent from a 4.5m deep pit (500m away), which included an additional 4m lift.

Andy Neal, Design Manager at MSE Systems, said: “Our challenge, which meant utilising a very small footprint between the existing plants, was to help our customer meet and maintain a stringent Environment Agency discharge consent, so that they remain fully compliant. The Landia AirJet and Chopper Pumps have proved very reliable and cost-effective, so it gave us the confidence to invest further in this equipment as the best, long-term solution.

He added: “For a new packing line, two submersible Landia Chopper Pumps will pump potato effluent, whilst a Landia Jet Mix system will mix organic sludge (dissolved solids 3-5%) in a 60m³ tank”.

MSE Systems ensured that the initial installation proceeded with the minimal amount of disruption, in order for their customer to reopen on schedule. Despite the tight time frame, the new wastewater treatment plant was delivered by MSE Systems ahead of deadline and within budget.

www.msesystems.co.uk

www.landia.co.uk

Whatever type of maintenance you regularly carry out, you need the right tools for the job. At Industry Superstore we stock extensive ranges of technical sprays, adhesives, sealants, and assembly pastes to meet all your requirements.

Effective Cleaning with our Industrial Cleaner

Machines, systems and production buildings need to be cleaned thoroughly on a regular basis. Our Weicon Industrial Cleaner has a powerful spray with high active ingredient content that ensures the fast and effective industrial cleaning of various surfaces - whether it's metal, plastic, wood or glass. The example shows the cleaning of a conveyor belt of a labelling machine in the beverage industry. That way, the cleaning agent contributes to minimising machine downtimes and thus to optimising operational processes.

Elastic Adhesives and Sealants (An Example)

Elastic adhesives and sealants are used today in many areas of industrial production and assembly. They combine the advantages of adhesive bonding and sealing technology and are used wherever the elasticity and the sealing of a joint are the most important requirements.

Weicon Black-Seal adhesive and sealant is black, high-temperature resistant (+280°C/+536°F), free of solvents, strong, oil-resistant, grease-resistant, pressure-resistant, resistant to ageing and extremely elastic (breaking elongation of approx. 500%).

Black-Seal is suitable for bonding and sealing in applications where particularly high oil and grease resistance is required. Black-Seal can be used on gearbox, valve and casing covers, oil sumps, water pumps, gears and axles, flanges, tanks and containers, and in many other areas.

Anti-Seize Assembly Paste

Our heat-resistant Weicon Anti-Seize Assembly Paste provides ideal protection against the worry of corrosion and wear. The metal-free lubricant is suitable for any material and can be used on wheel rims, brake blocks, brake drums, stud bolts or wheel bolts. The lubrication and greasing of all components with Anti-Seize Assembly Paste also increases occupational safety during production.

Got a project that you need help with?

At Industry Superstore we stock the solutions to your needs. Our ranges are growing constantly. Please have a look at our website and also our social media posts.

For assistance with your application please call ISS on (+44) 01892 664499, email This email address is being protected from spambots. You need JavaScript enabled to view it. or visit https://industrysuperstore.co.uk/

US-based surface protection solutions provider, Integrated Global Services (IGS), has been accredited with the esteemed ISO 9001 standard after an extensive two-day audit.

Following an ISO audit, Integrated Global Services (IGS) has been certified with the new ISO 9001:2015 standard for its Quality Management System (QMS). The certification recognises the company’s dedication to meeting customer requirements and maintaining its documentation, demonstrating to clients that its products and services meet all international quality standards.

Headquartered in Virginia, USA, IGS provides essential surface protection solutions for mission-critical equipment in a variety of industrial environments, all of which help to prevent equipment failure and drastically extend service life. A detailed audit of its Quality Management System (QMS) led accreditors to recognise the company as being worthy of the widely sought-after ISO 9001 standard. 

The team at IGS’ Tech Solutions is responsible for more than 100 pieces of performance qualification equipment, which are all operated through a complex management system. This system was highly praised by the auditor, whose report highlighted IGS’ ‘very thorough QMS that covers [the company’s] unique processes’. 

Iain Hall, Chief Technology Officer at Integrated Global Services, said; “We’re thrilled to have been accredited with the ISO 9001 certification. The auditor communicated that most companies take a template and try to squeeze their widget manufacturing into the same QMS. Our team was congratulated for taking the time to write our own, comprehensive QMS.”

“One aspect of the audit that was particularly commended was the traceability of our manufacturing materials. Random samples were tested, and supplier certifications were traceable to source to a level beyond the required standard and expectations.”

“I’m very proud of our team for their consistent efforts in ensuring quality for our clients, which has now been formally recognised by ISO. We will continue developing our QMS to deliver innovative and customised solutions to our customers”.

IGS' in-house state-of-the-art laboratory and research center provides their customers with the most accurate forecast of the performance of any field application.Watch a short video showcasing some of its capabilities.

www.integratedglobal.com

IFS Ultimo and digital transformation expert, SolutionsPT have signed a partnership to support asset-intensive companies in the UK and Ireland in optimising their asset management. IFS Ultimo’s solution will become part of the growing network of companies that aid SolutionsPT in achieving the goal of digital transformation for every industrial enterprise. For IFS Ultimo, this partnership marks a new significant step in its global growth strategy.

IFS Ultimo’s EAM technology helps businesses to manage their physical assets. The partnership enables SolutionsPT to support customers with increased asset uptime and lifespan, creating a safe working environment while cutting down on maintenance costs. Next to this, IFS Ultimo easily integrates with AVEVA software, providing another vital piece of the digital transformation puzzle. Now, SolutionsPT can offer an integrated solution, while combining real-time and operational information to seamlessly work alongside IFS Ultimo’s EAM. This results in a path to clear management and execution of actions to improve overall efficiency.  

Fayez Fares, APM Technical Lead at SolutionsPT, comments on about the partnership:
“We are excited to partner with IFS Ultimo and include the impressive Enterprise Asset Management platform as part of our expert offering to customers. As AVEVA Select Partners for the UK & Ireland we are well versed in world-class solutions and IFS Ultimo’s easy integration with Insight, System Platform, and Asset Strategy Optimization will only strengthen our offering to customers, creating a win-win solution for both our customers and ourselves. Our partnership with IFS Ultimo is another element of our step-by-step approach which can effectively achieve digital transformation for every industrial enterprise.”

Marcel Leeflang, Head of Channel Sales at IFS Ultimo, adds: “Customers from SolutionsPT will benefit from having a single point of contact for all their industrial software-related demands. The market specialists from SolutionsPT have years of experience in providing industrial software services. Therefore they are a logical partner for us to expand our business with. Next to AVEVA’s APM focussed software, they can now close the loop for customers by adding the maintenance part to their portfolio. This allows their customers to take the right action, with the right asset, at the right time. Our software stands out in optimizing Asset management processes and realizing a safe working environment, which becomes more and more important these days.” 

http://www.ultimo.com/

In industrial settings, screw connections need to be secured in many different places. For example, on adjusting screws, countersunk screws and set screws in industrial facilities – in fact, everywhere where components are exposed to increased movements and the safety of the construction is put under strain.The purpose of threadlockers is to prevent connections from loosening unintentionally and losing their clamping force.Traditionally, locking devices such as toothed lock washers or self-locking nuts are used for this purpose.

But the use of anaerobic adhesives for securing connections is also becoming increasingly popular. Chemical threadlocking prevents the screws from loosening even more reliably and with less material damage than traditional mechanical methods.

Anaerobic adhesives are single-component adhesives that remain liquid as long as they are in contact with oxygen. Only when oxygen no longer reaches the adhesive and there is metal contact it cures. This happens, for example, when a bolt and nut have been joined together. The screw connections are permanently secured, withstand vibrations and other forces, and are material-neutral and gentle on the material.

Are Anaerobic adhesives all good?

Not quite. Many of the anaerobic adhesives currently in use are labelled with hazard symbols and subject to H and P labels – so-called danger and safety statements.

For users, this can mean irritated skin, eyes and breathing tracts. The unpleasant smells caused by these adhesives are sometimes so extreme that daily work with them – especially in closed rooms – is very unpleasant.

In certain sensitive industrial sectors – such as the food or pharmaceutical production – place particularly high demands on the substances used there.

The Good News !

With a total of 20 types in the Weicon Lock Range at Industrysuperstore, we offer special anaerobic adhesives and sealants complying with strict guidelines. Therefore, they can be used in many sensitive areas, like the production of food, cosmetic products or medicines, and also serve to increase workplace safety.

WEICONLOCK adhesives have approvals from the National Sanitation Foundation (NSF) and the German Technical and Scientific Association for Gas and Water (DVGW), among others, and are suitable for use in drinking water applications. In addition, WEICONLOCK adhesives have a so-called “white” safety data sheet, which means that they are label-free and classified as non-hazardous.

For more information on the Weicon Lock Range please call ISS on (+44) 01892 664499, email This email address is being protected from spambots. You need JavaScript enabled to view it. or visit https://industrysuperstore.co.uk/

About Industrial Superstore: ISS, a subsidiary of PVL Ltd, is an online store offering industrial and commercial customers the largest range of industrial valves, seals, absorbent booms, pillows, socks, surface wipes, sanitation products, tools, handheld instruments and much more.

ISS is an online source for adhesives, sealants, technical sprays, hoses and fittings, flood prevention, spill kits and containment products, tools, hand sanitisers, disinfectants, industrial surface wipes, hand driers, dispensers and more.

PVL has been established for more than 25 years and has grown into the premier UK distributor for major manufacturers worldwide of pressure switches, vacuum switches, flow switches, level switches, level sensors, pressure transducers, pressure gauges, flow meters, float valves, level sensors, temperature switches and handheld instruments. The company also offers a full range of ATEX products.

Industrial Superstore
Unit 9 Lexden Lodge Industrial Estate
Jarvis Brook
Crowborough
TN6 2NQ

Phone:(+44) 01892 664499
Email: This email address is being protected from spambots. You need JavaScript enabled to view it.
https://industrysuperstore.co.uk/

”This case study describes the process of using the correct condition monitoring technique to monitor Rotating Biological Contactor (RBC) main bearings at 1RPM”

Severn Trent Water Asset Care Team were tasked with finding a reliable condition monitoring solution to monitor the main bearings of these RBC’s as when they fail they have huge consequences to the business. These RBC’s are usually located in remote sites and are difficult to keep track of with each area maintenance team having planned inspections but no real idea of condition.

SPM HD is proven to be the ideal condition monitoring solution for monitoring the lubrication decrease and early signs of damage on these bearings, other techniques such as ultrasound or Vibration Analysis could not detect these problems during previous trials. Due to SPM Technology proving itself Severn Trent Water decided to start with purchasing a Leonova Emerald initially then after presenting to the Directors they decided to invest in the same portable instruments for every area in waste water for Severn Trent. 38 Leonova Emerald instruments.

Rotating Biological Contactors (RBC) are an essential part of the water industry in remote areas. The RBC process allows the wastewater to come in contact with a biological film in order to remove pollutants in the wastewater before discharge of the treated wastewater to the environment. 

Fig.1 A remote site with 2 RBC enclosures

Each RBC consists of a main bearing at either end of the main shaft. One side of the RBC has a Motor/Gearbox. The speed of the main bearings are fixed usually between 1.8rpm and 0.9rpm depending on the size of the RBC. The length from one main bearing to the other also varies depending on the type of RBC installed.

Fig.2 Construction of an RBC

Small discs with Biological fluid are in close proximity to each other which is called media. As the RBC rotates slowly these discs treat the water which then moves to the next part of the Treatment process.

There are over 500 RBC’s in Severn Trent Water in different locations around the area. They are all in remote sites which are difficult to access. When a main bearing fails they have to plan in the replacement which can take months as the lead time on the bearings is long as well as the installation of cranes and lifting equipment to remove the RBC. 

Severn Trent Water had a number of these catastrophic failures resulting in them deciding to make plans to trial condition monitoring equipment. 

The initial readings on this asset was shown to be high in comparison to all other RBC’s. The below shows the overall SPM HD measurement results. The bearing was checked and repacked with grease showing a decrease in reading up until October

The overall SPM HD reading derives ultimately from the time signal reading below. This was confirmed that there was large impacts in the pressence of low readings indicating damage.

Corresponding Time signal

On relacement clear score marks could be seen around the shaft and damage was seen around the casing of the bearing and rollers. If this was left without monitoring it would have catastrophically failed.

Fig.9 Bearing pictures on replacement

After planned replacement the SPM HD readings reduced from alarm state to acceptable levels. The graph below shows the point when the bearing was replaced around the 20th November.

SPM HD Trend throught measurement lifetime

Time signal from healthy bearing

The British Compressed Air Society (BCAS) welcomes the Government’s new Energy Bill Relief Scheme, which comes into effect from tomorrow, the 1st of October - but is encouraging compressed air users to also act now to minimise their compressed air energy consumption for the long-term through a series of low-cost measures.

With 10% of all the energy consumed by industry used to compress air, any Government programmes which can help mitigate for the unprecedented rise in the cost of business energy are very welcome, says Vanda Jones, Executive Director at BCAS.

“The scheme will apply automatic discounts to the price of business energy usage initially between 1 October 2022 to 31 March 2023.^[1] While this will offer some relief to manufacturers and operators already struggling with soaring bills, the six-month time frame may not be sufficient to assist many end-users in the medium to longer term.

"Indeed, the cap still means that electricity prices for business customers will be around double the price per megawatt hour compared to this time last year.  Add to this the fact that generating compressed air can be very energy-intensive, representing as much as 30 per cent of a site's total electricity bill, and it is well worth operators considering further energy saving measures to help reduce their energy consumption, and therefore the cost burden further."

Earlier this year, BCAS launched its 10% Taskforce campaign, designed to encourage compressed air users to take simple steps to cut their compressed air energy figure by 10 per cent, by reducing wasteful and inefficient practices.  Vanda Jones continues:

"At the time we launched the campaign in April this year, we could not have predicted the huge rise in the wholesale gas and electricity prices. Our original calculations of £485.43 million being spent in wasted electricity have now risen two or even three-fold - meaning that the assistance now being offered through the Energy Bill Relief Scheme is vital.

"Since the launch, our members have been speaking with customers to encourage them to take action and to dispel some of the commonly-held beliefs that saving energy will require significant investment in new capital equipment.

"We have been demonstrating to operators that taking small, incremental steps can have a significant impact on reducing energy consumption.  This can include better housekeeping routines to avoid wasteful practices, fixing air pipework leaks, recovering heat which would otherwise be lost to the atmosphere, or implementing routine system maintenance."

The Society has a dedicated website at taskforce10.bcas.org.uk containing a host of end users hints and tips of simple ways that compressed air energy consumption can be reduced.  Free, downloadable guides are available (taskforce10.bcas.org.uk/simple-steps) as well as an area highlighting real examples of energy-saving measures that customers have implemented.

Businesses looking for further information and advice on ways to reduce compressed air energy consumption can contact their local BCAS member or visit taskforce10.bcas.org.uk

^[1] https://www.gov.uk/guidance/energy-bill-relief-scheme-help-for-businesses-and-other-non-domestic-customers

 

 
Accurately Measure and Log Dew Point Data to Improve Manufacturing Quality and Performance
 

GOLETA, Calif. – Sept. 27, 2022 ― Teledyne FLIR, part of Teledyne Technologies Incorporated, today announced the Extech RH600 Dew Point Meter for accurate and fast dew point temperature measurement primarily positioned to prevent problems associated with water vapor in compressed air systems.
As part of a predictive maintenance program in manufacturing environments, the Extech RH600 provides measurement down to -50°C (-58°F) with an accuracy of ±2 °C (±3.6 °F) over the entire range pressure, up to 20 bar. The Extech RH600 is ideal for monitoring dew point across long periods of time, including for monitoring switch behavior within the drying process and better optimizing energy consumption.

“For inspectors who require the convenience and freedom to inspect multiple positions within a compressed air system, the Extech RH600 provides the ideal form factor at a competitive price to capture accurate readings and then data log that information as part of an integrated predictive maintenance program,” said Rob Milner, director of business development, Teledyne FLIR. “The Extech RH600 is also optimal for low-humidity measurement with high accuracy, but should the sensor get wet, it can withstand the condensation and fully recover for future use.”
The included RH601 dew point probe provides accuracy and long-term stability. Users can directly insert the probe sensor into the compressed air system through a G half-inch thread, ensuring reliable readings with increased peace of mind, knowing the probe will dry quickly after moisture contact. The highly sensitive probe provides inspectors the ability to measure relative humidity at less than 5 percent and with high accuracy (±0.025 percent).


Data Logging for Predictive Maintenance
Users can easily monitor dew point on the built-in color graphical display with a menu-based user interface. They can program high/low set points for temperature as well as relatively humidity and dew point with visual and audible alarms. The device also enables logging and transferring up to 32,000 datasets to a PC in CVS format via a USB cable connection. The easy data transfer provides inspectors all key datapoints to create inspection reports for colleagues and clients, as well as to integrate the data into broader predictive maintenance initiatives that consolidate and analyze data across multiple inspection types and equipment.

The Extech RH600 consists of the RH601 dew point probe, AC adapter, micro-USB-to-USB-A cable, a 3.7 V Li-ion battery, and a hard case for storage. For more information, including availability and pricing by region, visit www.flir.com/RH600.

Aquapak Polymers, a leader in polymer technology that offers excellent functionality, recyclability and environmental credentials, has partnered with Industrial Physics, a global packaging, product, and material test and inspection partner, to create a harmonised set of WVTR (Water vapour Transmission Rate) testing methods for its Hydropol™ biodegradable polymer.

Hydropol offers all the benefits of traditional polymer plastics yet is water soluble and completely biodegradable as well as non-toxic and UV resistant. It also offers multiple end-of-life options such as recyclability, compostability and compatibility with anaerobic digestion plants.

Establishing a reliable and repeatable test method for WVTR is an industry-wide challenge. By using equipment designed by Industrial Physics’ product lines, including Systech Illinois, and Testing Machines Inc., Aquapak resolved to find a way forward by partnering with Industrial Physics, which will ultimately provide its customers across a wide range of sectors with a real alternative to using traditional polymers, helping them cut plastic pollution in the process.

Industrial Physics is a global test and inspection partner that works across a wide range of industry sectors to help customers protect the integrity of their packaging, products, and materials. The business is passionate about helping customers move to new, more sustainable packaging materials. The group is made up of numerous specialist testing brands, including Systech Illinois, TQC Sheen, Quality By Vision, Eagle Vision, Steinfurth, Technidyne, RayRan, Testing Machines Inc., and many more.

As more organizations continue to strive for sustainable alternatives, it’s unsurprising that demand for Aquapak’s Hydropol continues to grow – this is supported by Industrial Physics’ research that surveyed 255 packaging professionals around the world, highlighting that testing of new sustainable materials was a major challenge they face.

Almost half of the 255 global packaging professionals (49%) surveyed said meeting testing standards was one the biggest challenges they faced in wider adoption of sustainable packaging materials.

An example of this is that current WVTR test methods and standards are based around traditional polymers rather than sustainable, biodegradable alternatives such as Hydropol.

In order to continue their drive towards sustainable innovation in a way that didn’t sacrifice the integrity of their product, Aquapak approached Industrial Physics to support them in developing a repeatable and reliable test method for WVTR (Water Vapour Transmission Rate) for its Hydropol biodegradable polymer. 

The WVTR test method is a known challenge for hydrophilic polymers, and the team at Aquapak were looking to utilise knowledge and resources from Industrial Physics to develop a testing method that could be carried out in-house as well as replicated at its customers premises wherever they were in the world. 

Max Phippard, Quality Control Manager at Aquapak said: “Allowing the WVTR test to reach equilibrium means that we are confident in the results. Over the last few months, we have carried out full analysis of multi-layer samples to gain an understanding of how our customers can replicate their own WVTR testing regime on Hydropol.”

He continued: “Being able to build a relationship with Industrial Physics and leverage their expertise in packaging barriers was critical to the success of this programme.” 

Alan Shema, Product Line Director at Industrial Physics said: “We have reached a point where the WVTR test on Hydropol can be replicated anywhere in the world by using the approach taken by Aquapak and ourselves. This is a major step forward because it will shape how hydrophilic films are tested in future. It allows our global customers who source sustainable packaging materials such as Hydropol to carry out their own WVTR knowing they can trust the results.”

Phippard added: “As highlighted in Industrial Physics’ research, businesses face challenges when looking to switch to new, sustainable packaging materials. Developing a WVTR approach for Hydropol is one of the ways we are supporting our customers as they take this journey.

Industrial Physics offers a range of packaging, product, and material integrity testing solutions to food and beverage, flexible packaging, medical, pharmaceutical, and coatings markets. The company adopts a collaborative approach with customers to help them work through the challenges of moving to sustainable packaging. 

Industrial Physics carried out research with 255 packaging professionals earlier this year. Full results can be view at Industrial Physics Sustainable Packaging Research Report.

For more information about Industrial Physics click here.

To find out more about Aquapak, visit: https://www.aquapakpolymers.com/