Pepperl+Fuchs, one of the leading suppliers in this industry, is launching measuring inductive distance sensors featuring IO-Link interface. The devices are suitable for Industry 4.0 applications and offer not only high-precision measurement capabilities, but also comprehensive information for condition monitoring and predictive maintenance.

The sensors can detect objects at a speed of up to 3 m/sec and deliver precise measurement data with a repeat accuracy of 5 percent. Their measuring range is up to 30 mm. The sensors determine the speed and acceleration of the damping element. Two independent switching windows and defined limit values can be individually parameterized. Adjustable filters allow the measurement speed and accuracy to be adjusted. The high switching frequency of up to 1300 Hz enables very short throughput times, thereby helping to increase productivity.

Additional data, including temperature and operating times and counters, is transmitted via the IO-Link interface. The monitoring of speed and acceleration and the historical values of these variables allow the detailed analysis of sub-processes such as opening/closing for valves and acceleration/braking for absorbing elements. This monitoring of the machine status facilitates predictive maintenance and prevents unplanned downtimes. Devices with analog outputs are also available for classic applications.

Caption: The inductive distance sensors are available in several sizes and designs.

Caption: Valve position feedback with inductive sensors

www.pepperl-fuchs.com

Data center maintenance teams have a big share in safeguarding the critical resource that customers and businesses depend upon. Fortunately, they have one secret weapon that enables them to spot issues in an early stage before they turn into big problems: FLIR thermal imaging.

 

FLIR Exx-Series

 

The data center market has seen a massive growth in recent years. Spurred by a growing adoption of cloud technologies, AI, IoT, 5G and big data, new data centers are being built across all continents at fast pace. Whether they are in-house data centers for some of the largest and most influential companies, or built by specialized vendors offering infrastructure services, data centers fulfill a critical role in maintaining the continuity of a business. Downtime of a data center can have an enormous economic impact and needs to be avoided at all costs. In addition to financial loss, reputational damage can be equally impactful, especially when the data center is supporting customer-facing services.

Guaranteeing uptime has become increasingly complex for data centers. With so much mechanical, electrical and electronic infrastructure under one roof, overheating is a major concern, not only because the infrastructure is not using the energy efficiently, but also because overheating can cause a complete shutdown of servers, impacting users around the world, or even data or equipment loss. One of the most reported incidents is the 2013 overheating of a Microsoft data center operating some of its cloud services, including Outlook, which led to services being lost for 16 hours.

MAINTENANCE INSPECTIONS WITH THERMAL IMAGING CAMERAS

The maintenance of a data center today involves much more than IT operations. Power distribution systems and cooling infrastructure are also essential for keeping the data center up and running, and for preventing mechanical or electrical failures and resulting outages.

Many systems that are critical for the data center’s operation heat up before they fail. Temperature is an important indicator of energy consumption and equipment operation, which is why infrared thermography (thermal imaging) is an ideal tool to inspect power consumption, electrical installations, cooling equipment and computing hardware.

Periodic inspections with a thermal imaging camera have become indispensable in predictive and preventive maintenance programs. Thermal cameras help maintenance staff to detect problems in electrical switchgear, motors, HVAC infrastructure, uninterruptible power supplies (UPS), power distribution units (PDU), batteries and generator equipment and all electrical devices that feed the server systems, before these problems turn into serious failures or downtime.

With cloud computing becoming the new normal, and as data centers are growing to great scales, the need for higher computing density and power efficiency is growing as well. Data center owners are seeking ways to increase their capacity, but they also want to reduce costs and energy. Thermal imaging can give them important information on how to optimize energy and space requirements, without causing overheating.

In short, regular inspections with thermal imaging cameras can help maintenance staff to:

• Find and fix hidden problems before they turn into unplanned
• Reduce the chance of component degradation going unnoticed due to overloaded circuits or loose connections.
• Prevent equipment breakdowns
• Optimize energy management and space allocation

WHAT IS THERMAL IMAGING?

A thermal camera is a non-contact device that detects infrared energy (heat) and converts it into a visual image. Infrared radiation lies between the visible and microwave portions of the electromagnetic spectrum.

Any object that has a temperature above absolute zero (-273.15 degrees Celsius or 0 Kelvin) emits radiation in the infrared region. Even objects that we think of as being very cold, such as ice cubes, emit infrared radiation. Thermal cameras turn this invisible energy into something that can be seen on a screen and measured.

 The themal spectrum

 

THE BENEFITS OF THERMAL IMAGING

Why would you choose a FLIR thermal imaging camera? Sure, there are other technologies available to help you measure temperatures – infrared thermometers or thermocouples to name only two. But no other tool is as powerful and efficient as a FLIR thermal imaging camera.

SEE THE WHOLE PICTURE

Unlike IR thermometers or thermocouples, thermal imaging cameras enable you to scan large areas for hot spots or temperature differences. Without a thermal camera, it’s easy to miss critical parts like air leakages, areas with insufficient insulation or water intrusion. A thermal imaging camera can scan entire electrical installations, buildings, heating or HVAC installations. It never misses a potential problem area no matter how small this might be. They also allow you to compare temperatures of components in the same

MAINTENANCE INSPECTIONS WITH THERMAL IMAGING CAMERAS

The maintenance of a data center today involves much more than IT operations. Power distribution systems and cooling infrastructure are also essential for keeping the data center up and running, and for preventing mechanical or electrical failures and resulting outages.

Many systems that are critical for the data center’s operation heat up before they fail. Temperature is an important indicator of energy consumption and equipment operation, which is why infrared thermography (thermal imaging) is an ideal tool to inspect power consumption, electrical installations, cooling equipment and computing hardware.

Periodic inspections with a thermal imaging camera have become indispensable in predictive and preventive maintenance programs. Thermal cameras help maintenance staff to detect problems in electrical switchgear, motors, HVAC infrastructure, uninterruptible power supplies (UPS), power distribution units (PDU), batteries and generator equipment and all electrical devices that feed the server systems, before these problems turn into serious failures or downtime.

With cloud computing becoming the new normal, and as data centers are growing to great scales, the need for higher computing density and power efficiency is growing as well. Data center owners are seeking ways to increase their capacity, but they also want to reduce costs and energy. Thermal imaging can give them important information on how to optimize energy and space requirements, without causing overheating.

In short, regular inspections with thermal imaging cameras can help maintenance staff to:

• Find and fix hidden problems before they turn into unplanned
• Reduce the chance of component degradation going unnoticed due to overloaded circuits or loose connections.
• Prevent equipment breakdowns
• Optimize energy management and space allocation

WHAT IS THERMAL IMAGING?

A thermal camera is a non-contact device that detects infrared energy (heat) and converts it into a visual image. Infrared radiation lies between the visible and microwave portions of the electromagnetic spectrum.

Any object that has a temperature above absolute zero (-273.15 degrees Celsius or 0 Kelvin) emits radiation in the infrared region. Even objects that we think of as being very cold, such as ice cubes, emit infrared radiation. Thermal cameras turn this invisible energy into something that can be seen on a screen and measured.

The themal spectrum

 

THE BENEFITS OF THERMAL IMAGING

Why would you choose a FLIR thermal imaging camera? Sure, there are other technologies available to help you measure temperatures – infrared thermometers or thermocouples to name only two. But no other tool is as powerful and efficient as a FLIR thermal imaging camera.

SEE THE WHOLE PICTURE

Unlike IR thermometers or thermocouples, thermal imaging cameras enable you to scan large areas for hot spots or temperature differences. Without a thermal camera, it’s easy to miss critical parts like air leakages, areas with insufficient insulation or water intrusion. A thermal imaging camera can scan entire electrical installations, buildings, heating or HVAC installations. It never misses a potential problem area no matter how small this might be. They also allow you to compare temperatures of components in the same

environment more easily.

SAVE TIME AND COSTS

Maintenance of data center installations can be labor-intensive. Because they can easily see larger surfaces, thermal imaging cameras can be the solution to reduce maintenance time speed up inspection rounds, and still see all impending failures, before they turn into costly defects.

INSPECT WITHOUT SHUTTING DOWN

Thermal imaging is a non-contact technology. This is a safe method, because maintenance personnel can keep a distance without having to touch hot items. But it also means that inspections can easily be carried out while the equipment is still running or under load. There’s no need to foresee costly downtime. Some inspections, for example rotary UPS systems, can only be done during operation, which makes the thermal imaging camera an ideal tool for online inspections.

REPORT LIKE A PRO

Thermal imaging cameras allow users to make professional, more insightful reports of their inspections that also look great for management and customers. Users can compare current inspections with historical data and discover trends. Features like templates, batch processing, image editing and route planning further enhance the use-friendliness of today’s reporting solutions.

THERMAL IMAGING APPLICATIONS

Thermal imaging is the perfect technology to tackle the wide range of maintenance and inspection jobs for data centers.

ELECTRICAL AND MECHANICAL SYSTEMS

Thermal imaging cameras can be used to inspect a variety of electrical or power generation-related systems. Heat is an important indicator for defects in electrical installations. When current passes through a resistive element, it generates heat. Over time, the resistance of electrical connections can increase, due to loosening and corrosion for instance. The corresponding rise in temperature can cause components to fail, resulting in unplanned outages.

Electrical systems can also suffer from load imbalances and increases in impedance to current. Thermal inspections can quickly locate hot spots, determine the severity of the problem, and help establish the time frame in which the equipment should be repaired.

Thermal imaging cameras will help you to spot issues with:

• Overheated connections
• Overloaded or imbalanced circuits
• Damaged switches
• Faulty fuses
• Power supplies
• Battery systems
• Generator systems
• Uninterruptible Power Supplies (UPS)
• Transformers
• Electrical panels
• Resistive load banks

HVAC AND COOLING SYSTEMS

To run smoothly and efficiently, data centers need perfectly air-cooled conditions. Data centers are typically making use of a hot aisle/cold aisle layout principle. Server racks are lined up in aisles with the front sides facing each other. The cold aisles get cold air directly from the Computer Room Air-Conditioning (CRAC) unit from the bottom of the raised floor. The cool air cools down the servers on the racks. Meanwhile, the backs of the servers vent out hot air in the hot aisle, which then returns to the CRAC unit.

Thermal imaging has become increasingly important to verify the proper hot aisle/cold aisle operation,

especially because data centers today are condensing more servers into their racks. Thermal cameras will enable users to see problems such as misaligned ductwork and electrical faults, and then make decisions about corrective actions. HVAC inspection with a thermal imaging camera can help to:

• Monitor server rack temperature distribution patterns
• Locate misrouted and leaking ducts
• See electrical or mechanical CRAC unit defects
• Confirm the source of energy losses
• Find missing insulation
• Discover AC condensate leaks
• Find internal server fans which are inoperable or damaged

RENEWABLE ENERGY

Data center operators are increasingly improving their use of renewable energy sources, including solar and wind power. These renewable power sources enable data centers to reduce their environmental impact, whilst meeting long-term sustainability goals.

SOLAR POWER

The solar panel, the most important part of a solar system, must be reliable and capable of producing electricity for years on end. Unfortunately, solar panels are susceptible to wear. Maintenance professionals therefore use thermal imagers to inspect solar panels installed on rooftops or in solar parks to quickly pinpoint solar panel problems down to cell level.

Anomalies can clearly be seen on a crisp thermal image and - unlike most other methods – thermal imaging cameras can be used to scan installed solar panels during normal operation. Thermal imaging cameras also allow users to scan large areas within a short time frame.

WIND POWER

Wind turbine components are susceptible to wear and can break down. That’s why preventive maintenance and periodic inspections are so important. Thermal imaging is the only technology that allows users to inspect all electrical and mechanical components of the wind turbine and the surrounding electrical system, so they can detect a problem before a breakdown occurs.

A thermal imaging wind turbine transmission survey performed at a 50-meter height

 

FIRE PROTECTION

Although data center fires are relatively rare, they can have a devastating impact. Data centers may be equipped with fire alarms and firefighting systems, but once a fire starts, asset damage is almost certain. Fixed thermal imaging cameras can identify hot spots before they ignite and provide an early warning response to avoid a full-on destructive fire before assets are harmed or safety is compromised.

PHYSICAL SECURITY

Thermal cameras not only detect hot spots or temperature differences. They also help protect a physical perimeter against unwanted intruders or trespassers. As data centers operate 24/7, they need effective solutions to help them monitor the premises and detect threats around the clock. Thermal security cameras that offer high contrast, high resolution and long detection ranges are ideal for data center deployments.

Unlike standard video cameras, thermal cameras can see in most adverse weather conditions– such as light rain, fog, smoke, or total darkness. When integrated with video analytics, thermal cameras can distinguish between a human or vehicle. When paired with radar, customers gain redundancy and reduce the likelihood of a false positive. By combining thermal cameras with HD visible cameras, remote operators can review thermal and visible video streams of the scene for improved alarm verification and intruder identification.

THERMAL IMAGING SOLUTIONS FROM TELEDYNE FLIR HANDHELD THERMOGRAPHY CAMERAS

Armed with a FLIR thermal imaging camera, maintenance crews can easily diagnose a wide range of

problems across their data center facility. Available in a wide variety of sizes and image resolutions, FLIR thermography cameras always offer the highest accuracy and user-friendliness to meet the needs of maintenance professionals.

THERMAL STUDIO SOFTWARE WITH ROUTE CREATOR

FLIR Thermal Studio Suite is state-of-the-art analysis and reporting software designed to help data center maintenance teams manage thousands of thermal images and videos. Whether you use handheld thermal cameras or unmanned aircraft systems (UAS), the FLIR Thermal Studio suite of software provides the automation and processing capabilities you need to streamline workflow and increase productivity. The optional Route Creator plugin allows users to plan inspection routes in advance, complete inspections more efficiently and reduce reporting time by 50%.

Keep your thermal camera in optimal performance condition and avoid unforeseen downtime with a FLIR CARE service package. Whether you are looking for a performance verification service or a traceable calibration adjustment service, FLIR CARE’s traceable calibration services have you covered.

FLIR PROTECT Extended Warranty and Service Packages give you the peace of mind that your camera is protected from material defects and issues for three years after your factory warranty expires. Choose FLIR Protect+, FLIR Protect

Pro, or FLIR Total Protect to bundle a discounted FLIR CARE Service with your FLIR PROTECT extended warranty.

www.flir.com

 

Standards are very high at the acclaimed Urbana & Champaign Sanitary District (UCSD). Very High!

Offering a one-year guarantee on your equipment? Think again.

When the team at this Illinois treatment facility looked to upgrade the pumps on three of its anaerobic digesters, a lifetime of around 20 years was expected.

Almost eight years in, and the pumps that were installed on the 500,000-gallon digesters, are, according to Justin Profancik, Director of Operations at UCSD, ‘very dependable, reliable and durable’.

Situated approximately 140 miles south of Chicago, UCSD’s digesters were built separately over a period of years at its Northeast Treatment Plant (NEP), which opened in 1924 (UCSD’s Southwest Treatment Plant opened in 1968). In 2016, it was time for an upgrade, especially as the existing pumps were clogging up more or less on a quarterly basis.

“The old units had done a pretty good job,” said Justin Profancik, “but weren’t Chopper Pumps (*invented by Landia in 1950), so the solids, rags and grit would gradually accumulate, causing them to clog. We then had to take them apart and 

clean them out, so there was a lot more maintenance involved then, compared to now.

‘Maintenance department really likes the design’

 

“When we’ve inspected the Landia pumps (each 7.8HP) over the past seven years, there hasn’t really been anything of any major significance to worry about. On the Landia Chopper Pumps’ external knife system, you can change the blades easily. Our maintenance department really likes the design.”

Created over a century ago by voter petition, UCSD is a municipal body that provides wastewater treatment for properties in the Cities of Urbana and Champaign, as well as the villages of Bondville and Savoy. It also serves the University of Illinois (56,000 students). It is not a part of any other local, municipal, county, township or state government. Today, it employs 50 people, including 10 operation staff.

At UCSD’s Northeast Treatment Plant (NEP), solids management facilities include gravity belt thickeners to thicken waste activated sludge (WAS); a sludge receiving station that receives thickened waste activated sludge (TWAS) from the UCSD Southwest Plant (SWP), industrial WAS, high strength waste (HSW) from grease-hauling trucks and a small amount of food waste from a Hershey’s (chocolate) truck wash and the University of Illinois. There is also a tank that blends sludge 

from the receiving station with NEP TWAS and primary clarifiers; four anaerobic digesters (three of which are now served by the Landia Chopper Pumps); a digested sludge storage tank; and three centrifuges to dewater the digested sludge. The dewatered biosolids, which meet Class B biosolids requirements, are land-applied as soil amendment to agricultural fields.

Digester gas produced in the anaerobic digesters is used in combined heat and power (CHP) engines to cogenerate electricity and heat for the NEP, as well as export electricity to the grid.

 

‘Protecting downstream equipment’

“We call the Landia units our recirculation pumps,” continued Justin Profancik, “but (stored in the basement of our AD complex) they are part of the heating cycle, effectively working as recirculation pumps through our heat exchangers to heat the digesters. We used to have to clean the heat exchangers out about once per month, but with the Landia Chopper Pumps continuously chopping and reducing the particle sizes of the sludge, this is only required about once per quarter – and in those quarters, a lot of times, we're usually not really finding anything, even in the small veins of the heat exchanger. It 

shows in this case that top quality pumps play a big part in protecting downstream equipment.”

Since the installation of the Landia Chopper Pumps for the UCSD digesters, gas production has increased; hitting a record high of 400,000 cubic feet per day. Typically, though, it is around an average of 190,000.

‘Hershey truck wash’

Justin Profancik added: “Although the food waste we take in from the Hershey truck wash is less than one per cent of our feedstock, we can see the difference in gas production immediately.”

As a District that likes to use its money very effectively and efficiently, UCSD more than did its research into the new pumps that it needed for its digesters. This culminated in visiting Landia’s manufacturing facility in Lem, Denmark, which came about through the Water Technology Alliance (WTA), an outreach program to share valuable water technology solutions between the North American and Danish water sectors. Wade Lagle, previous Director of Operations at UCSD (who has over 40 years’ experience in wastewater treatment), explained:

“Seeing where and how the pumps were made gave us very positive reassurance,” he said. “The quality control and cleanliness of the facility was second to none. It is a wonderful 

production facility. We could see that the Landia Chopper Pump is very well designed, and that it would be a very good fit for our digesters, low on maintenance, highly effective, and with a long lifetime. Total cost of ownership is very important to us.”

Justin Profancik continued: “Installation was very straightforward, and because the pumps haven’t had any major issues, we’ve not had to make that much contact with Landia, but when we do, they’re always there with help and advice, wanting to ensure that everything is right. We’ve had really great success with the Landia Chopper Pumps.”

 

Plant Background

The Idbäcksverket combined heat and power (CHP) plant, operated by Vattenfall since 1997, is a vital energy facility in Nyköping, Sweden. The plant plays a crucial role in the region's energy infrastructure, providing approximately 95 percent of the Nyköping urban area with district heating and electricity. Aligned with Vattenfall's commitment to fossil freedom, the facility primarily utilizes renewable fuel sources, with the majority consisting of industrial and forestry waste.

Plant Facts

Country	Sweden
Electrical power	35 MWe
Heating effect	234 MWth
Technique	CHP power plant
Main fuel	Biomass

 

The Challenge

At this power facility, a biomass-fired Bubbling Fluidized Bed (BFB) boiler that processes waste wood was facing erosion and corrosion wastage, particularly affecting the waterwall surfaces, a common challenge in biomass boiler operations. As a major energy producer in the region, maintaining reliable operations at this renewable energy facility is crucial. This degradation posed a significant risk to operational reliability and could potentially lead to unplanned outages due to tube leaks.

The Solution

The plant approached Integrated Global Services’ (IGS) European division for a solution to stop the metal wastage issues. To address the issue, IGS deployed its proprietary High Velocity Thermal Spray (HVTS) cladding technology, a  proven solution for protecting biomass boilers against aggressive operating conditions. This solution focused on the lower section of the furnace, treating approximately 100m² of surface area to protect and extend the lifetime of the aging weld overlay.

The project scope also included the protection of the carbon steel waterwalls in the upper furnace section and the connecting roof area between the furnace and second pass, ensuring comprehensive protection throughout critical areas of the boiler.

HVTS is applied at a nominal thickness of 500 microns. The technology works by creating dense protective layers while minimizing internal stresses. The process applies ultra-fine particles in a dense pattern, creating longer pathways from surface to substrate that effectively prevent permeation. This corrosion-resistant alloy (CRA) cladding creates a robust barrier against further material degradation.

A key advantage of HVTS is its ability to protect and extend the life of existing panels with minimal remaining thickness, eliminating the need for intensive panel replacements. In areas with existing Inconel protection, HVTS provides an effective method to further extend the operational life of these critical boiler components, offering a cost-effective alternative to complete panel replacement.

 

 

Implementation Timeline

The plant has implemented a systematic biomass boiler protection program over several years:

• 2020: Initial application covering 35.0 m²
• 2022: Major expansion to 158.0 m²
• 2023: Additional 80.0 m² coverage
• 2024: Latest refurbishment of 17.0 m²

All projects were completed on time with zero safety incidents.

 

Inspection Results

Regular inspections were conducted to verify the cladding's performance. Thickness measurements were taken every 300mm and detailed mapping of application areas was conducted.

Inspection results showed that the cladding was in excellent condition with consistent thickness readings above 400 microns.

Benefits of the Project

Enhanced Protection

• The HVTS cladding successfully prevented further erosion and corrosion of the biomass boiler surfaces.

Minimal Operational Disruption

• Can be applied simultaneously with other maintenance tasks such as tube replacements in other boiler sections, as the process doesn't generate heat-induced distortion. This enables efficient maintenance planning and reduced outage time.

Non-Invasive Application

• No heat-related distortion, making it ideal for sensitive components like hanger panels and dividing walls.
• No pressure testing required for the protected area.

Flexible and Customizable

• Possibility to customize the alloy for specific wear mechanisms
• Repairable unlike other protection processes
• Can extend the life of existing panels, including those previously protected with Inconel

Quality Assurance

• Post-application inspections confirmed uniform coverage and quality, ensuring long-term protection.

Safety Excellence

• Zero safety incidents throughout the project execution. IGS Europe is ISO 45001:2018 certified and follows OSHA best practices and all local safety regulations, whichever is stricter.

Future Recommendations

Based on the successful implementation and monitoring results, the following recommendations were made:

1. Regular inspections during scheduled outages to monitor cladding performance

2. Proactive identification of additional areas requiring protection

3. Continued monitoring of existing applications to optimize future maintenance schedules

Conclusion

The systematic application of HVTS cladding technology has proven to be an effective solution for protecting biomass boiler surfaces against erosion and corrosion.

IGS has performed over 4,000 site projects and installed millions of square feet of reliable surface protection across the globe. IGS enables plants to avoid costly equipment replacements without sacrificing long-term reliability of boilers and vessels.

https://integratedglobal.com/services/on-site-hvts-cladding/

Producing a customized explosion-proof high-voltage motor within just 12 calendar days, Menzel Elektromotoren saved an oil refinery a considerable amount of money. The failure of the previously installed compressor motor was causing enormous financial damage. The team of the German family business Menzel worked on this project with considerable commitment, including weekend shifts, and thus completed all necessary works in record time. An in-stock MEBKSW-type three-phase squirrel-cage induction motor in size 710 was enabled for ignition protection type Ex ec, increased safety, with purging. Menzel’s certified explosion protection experts gave it the ATEX marking II 3G Ex ec IIA T3 Gc and prepared the extensive documentation required by the customer within the tight time frame.

The motor generates an output of 10 MW and 64132 Nm rated torque at 6600 V rated voltage. It features IP55 protection and IC 81W cooling (air-to-water heat exchanger) and is suitable for outdoor installation and the increased ambient temperature range of -20 °C ... 48 °C. To ensure a smooth installation in the existing plant environment, Menzel made various mechanical adaptations such as machining the motor shaft, manufacturing a new base frame and providing flanges for the purging device.

More about electric motors with ignition protection type Ex ec, increased safety: https://www.menzel-motors.com/ex-na/

 

To coincide with this year's National Apprenticeship Week, the British Compressed Air Society (BCAS) has launched a new apprenticeship pack, to guide employers, apprentices and their parents throughout the process.

Included in the pack is a new best practice guide for employers, to support the recruitment, management, and development of apprentices in the compressed air and vacuum industry.

The guide offers comprehensive advice on apprenticeship structures, recruitment strategies, mentoring, and legal obligations, helping businesses attract and nurture new talent. It highlights the importance of paid apprenticeships, structured induction processes, and safeguarding measures, ensuring apprentices receive the best possible start to their careers.

In addition, a handy guide for apprentices explains the areas to consider when choosing an apprenticeship and what to expect during studies. Plus, there is a step-by-step overview for parents and guardians that are keen to support their child to get the best out of their new career.

BCAS, alongside its members and the Institute for Apprenticeships and Education (IfATE), was instrumental in the development of a dedicated compressed air and vacuum industry apprenticeship, an industry first. 

The industry-specific pathway has already helped the next generation of skilled professionals, providing standardisation of their skills, competence, behaviours and safe working. The standard ensures that upon successful completion, the apprentice achieves a national apprenticeship, academic qualifications and may apply for the professional recognition of EngTech with The Society of Operations Engineers.

Continues…

However, as Terry Collier, Learning and Development Officer at BCAS explains, many businesses, especially those new to recruiting apprentices are keen to receive extra support.  He said:

"Many of our BCAS members are smaller SMEs that do not have access to large HR departments to assist with recruitment and training.  At the same time, these members have a highly skilled workforce made up of professional engineers that have a vast amount of knowledge and experience.  There is a real desire to pass this expertise onto the next generation, especially to help address the continuing engineering skills gap.

"Our new apprenticeship pack has been launched to help our members, and the wider compressed air engineering community achieve precisely this.  A key focus is on workplace integration, with guidance on creating a structured work plan, assigning meaningful tasks, and providing effective mentorship.

'In addition, our accompanying apprentice and parents' guides provide practical, friendly advice during this key stage in a young person's career."

The guide also outlines the recent government funding changes, including full funding for small and medium enterprises (SMEs) and increased flexibility in Apprenticeship Levy transfers.

BCAS members can download this pack. Please click here

The Combustion Engineering Association (CEA) is pleased to announce Michael Kaye as its new General Manager. With a strong background in mechanical and design engineering, coupled with years of industry leadership, Michael brings both expertise and a fresh perspective to this long-standing trade association and educational charity.

Graduating from Nottingham Trent University with a degree in mechanical engineering, Michael began his career as a design engineer at APV Baker PMC where he honed his technical skills before moving into leadership roles across various industries. His career spans sectors including textile testing instrumentation and bulk materials handling, where he earned a reputation for fostering innovation, building effective teams, and driving business growth. At Flexco, where he also served as General Manager, Michael led initiatives that not only grew the business but also set new benchmarks for industry standards.

In addition to his professional achievements, Michael has also been deeply involved in association work where, as a long-time member and former president of the Materials Handling Engineers Association (MHEA), he gained valuable experience in bringing members together, organising impactful events, and promoting technical excellence, skills that align perfectly with the CEA’s mission.

Commenting on behalf of the CEA, President Mick Casey shared his thoughts on Michael’s appointment: “We are thrilled to welcome Michael as our new General Manager. His leadership comes at a pivotal time for the CEA as we navigate changes across the combustion-related sectors, and his vision for enhancing member engagement and promoting sustainable practices will undoubtedly strengthen our role in the industry.”.

Michael himself expressed enthusiasm for his new role: “The energy sector is undergoing significant transformation as we tackle challenges including the adoption of alternative fuels, decarbonisation and achieving net-zero goals. I see the CEA playing a key role in driving these conversations and supporting our members with practical solutions. Together, we’ll focus on alternative fuels, energy efficiency, and sustainable practices.”.

One of Michael’s immediate priorities is overseeing the CEA’s transition into a Charitable Incorporated Organisation (CIO). He also aims to expand training programs such as the Boiler Operation Accreditation Scheme (BOAS) while building stronger connections with academic institutions to nurture future talent in combustion engineering.

Under his leadership, the CEA also plans to reinvigorate its events calendar with site visits, networking opportunities, and conferences designed to deliver real value to members. The first of these initiatives – a site visit to James Cropper’s paper mill scheduled for February 2025 – will combine technical insights with opportunities for collaboration.

For further information on CEA initiatives or membership opportunities, visit www.cea.org.uk, email This email address is being protected from spambots. You need JavaScript enabled to view it., or call 01740 625538.

I speak with hundreds of manufacturing decision-makers and industry experts at industry events about the major trends impacting the global manufacturing industry.

With output set to rise by three percent in 2025, it is clear that the future of the industry is bright. Judging by the conversations I have with people at the manufacturing frontline, this positive development is to a large degree driven by the increasing adoption of Industry 4.0 technologies and practices among businesses around the world.

As the industry grows smarter, here are my four key takeaways from my conversations with leading manufacturers. These major trends and innovations are highly likely to shape global manufacturing in 2025 and beyond.

1. Advancing Digitalization

In the world of manufacturing, digitalization is often synonymous with automation. This is something that manufacturers have always excelled at. Simultaneously, sensors and endpoints are widespread and their numbers growing, a noticeable upsurge from Gartner's 21 billion estimate back in 2020. What this means is that clearly, businesses can capture data like never before.

I expect that we will see accelerated efforts to augment automation with data to drive even smarter factories and equip decision-makers with unprecedented insights, especially when it comes to enterprise asset management (EAM). We should also expect digital twins—an area predicted to grow at a compound annual growth rate (CAGR) of 30 percent from 2023 to 2027—to play an integral role in this development as businesses look for intelligent ways to transform vast fields of unstructured data into a centralized model that helps visualize complex assets and improve collaboration between departments and functions.

As digitalization picks up even more momentum over the coming years, so will the associated risks. By digitizing processes and value chains, companies are exposing themselves to the threat of data security challenges, including malware incidents, loss of data, or Denial-of-Service (DoS) attacks that have the potential to cripple businesses. Given the magnitude of the risks involved, I believe that we will see increased focus among manufacturing businesses to invest in effective cybersecurity measures. This will, in turn, lead to an industry-wide strengthening of supply chain integrity.

Advancing digitalization and automation will naturally influence the workforce. However, rather than replacing those roles filled by humans, technology will instead be used as a tool to help improve the efficiency of personnel to make workdays more productive and flexible. In other words, when digitalization has automated those tasks that do not benefit from human intervention, workers are free to turn their attention to more complex tasks where value can be added.

2. AI-Powered Predictive Maintenance

As the above-mentioned figures from Gartner indicate, the industry is connecting assets at a furious pace. This increase in available data is the driving force behind an advancement in predictive maintenance initiatives, which I believe will help shape the manufacturing sector in the years to come. The most crucial component of any effort in this area is the EAM solution and how it connects to the company’s installed base of assets. After all, the more interconnected the EAM solution and your assets become, the more imperative it is to predict and project on asset failure. With the help of data-driven insights, predicting when a machine will fail will allow businesses to take measures to prevent this from happening.

The growing interest in predictive maintenance is hardly surprising given the financial incentives. For example, predictive maintenance can save up to 40 percent in costs compared to reactive maintenance and 8–12 percent when compared to preventive maintenance. Predictive maintenance can also extend asset lifespans by 20–40 percent. No wonder the market for these solutions is projected to grow to USD 47.8 billion in 2029 (CAGR 35.1 percent).

Artificial Intelligence (AI) is a key differentiator that will drive all major advancements in predictive maintenance for years to come. Making sense of and operationalizing sensory data, AI models will retain their looming presence in enterprise asset management as companies explore new ways of harnessing machine learning to enhance error detection and prevention, while also increasing energy efficiency.  

3. Purposeful Production

At the same rate the global population is growing, so is our demand for goods and services. To meet this demand, greenhouse gas emissions have increased by 50 percent over the last three decades. In 2023, according to the US Environmental Protection Agency, the manufacturing and raw materials industries accounted for approximately 23 percent of emissions, while manufacturing consumed some 33 percent of the world’s energy.

As a result of these rather sobering figures, I see a clear shift among manufacturers toward a more purposeful production wherein goods are made in a way that minimizes the environmental footprint, conserves resource and considers both the social and economic aspects of its impact.

What we are seeing now and in the coming years is a global shift to a circular economy that lets us reduce waste and use resources more efficiently. As these new imperatives are becoming reality, manufacturers will need to adopt technology to help implement lean processes, ensure increased productivity, minimize energy consumption, ensure supply chain traceability, enhance workplace safety and much more.

For the manufacturing sector, this is a sea change that imposes increasingly stringent demands on operations - not only in terms of supply chain visibility and raw material sourcing, but also when it comes to the emissions and energy consumption of their factories. For this reason, many businesses will need to overhaul production methods, maintenance practices, and reporting capabilities.

4. The Changing Workforce, and Skills Shortages

There’s a clear shift in the way maintenance departments operate that will reach a critical inflection point in 2025. As internal processes become increasingly digitized, maintenance workers must become more adept at using different technologies, tools and platforms. New skill sets are required around the collection, analysis and interpretation of data that will assure manufacturers are fit for the future.

The lack of skilled personnel is acute. A third (31 percent) of companies outsource operations because skilled individuals are hard to find, and over half (58 percent) of manufacturing employees have worked in the industry for more than 20 years. 

While manufacturers have been dealing with an aging workforce for some time, they would be wise to start hiring on skill sets that better match the technological requirements and advancements of tomorrow, versus talent that will follow directly in the footsteps of today’s engineers.

Looking further to the future, immersive technologies such as virtual reality (VR), mixed reality (MR), and augmented reality (AR) are set to redefine how all industries function. In the manufacturing sector, metaverse-based tools will unlock new vistas of opportunity. For example, VR technology can help staff to develop their skills without leaving the room. MR and AR can likewise empower workers to solve problems in the field by tapping into a central knowledge repository or by drawing on the skills of remote coworkers. Besides savings in time, cost and effort, reports suggest monumental increases in productivity of up to 20 percent. The business case for immersive technology is compelling.

Immersive technology holds the potential to revolutionize the way manufacturing operates, and the growing reliance on predictive analytics, AR, VR, and other advanced technologies will demand a workforce proficient not just in basic digital skills, but also in using these sophisticated tools in their daily work.

With a third of the manufacturing workforce at age 55 or older, businesses will be forced to make changes in order to attract younger generations of workers. Over the next few years, I believe that a vanguard of manufacturing businesses will start deploying immersive and other emerging technology to appeal to generation-now workers whose digital nativeness and low threshold for adoption will unlock new efficiencies and ways of working.

The Future is Bright

Despite some of the challenges outlined above, I see a bright future for the manufacturing industry. Speaking with customers, partners, and industry experts, it is clear to me that there has never been a more opportune moment to improve, streamline and innovate. Combining the potential of cutting-edge technology with the responsible and sustainable ethos of purposeful production, I am convinced that the manufacturing industry is ready to face the future.

www.ultimo.com

 

We aim to establish a directory of businesses supporting the steam industry, providing end users with a centralised resource for services, products and expertise. Our easy to navigate website features categorised sections which enables services to be located with ease. Additionally we utilise social media to share members services, products and case studies with a wide audience.

Our mission is to support business and end users of steam and boiler systems across manufacturing, process and industrial environments. By fostering a network that facilitates business to business interactions, we aim to address the growing scarcity of engineering disciplines in todays industrial sectors.

 

Our platform is broken down into key elements supporting the generation and distribution of steam. The main categories being:

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• Training Providers
• Components and Ancillaries
• Control and Automation
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• Water Treatment
• Chimneys and Flues
• Emissions

So how can Steam Network benefit me?

If you’re a Businesses supplying products, service into the steam industry:

By becoming a member of Steam Network UK offers businesses a unique opportunity to be listed under categories specific to their services and products. We will actively promote your business to our extensive network and end users. As the only directory dedicated to supporting the steam industry, Steam Network UK ensures that your services are showcased to key stakeholders in need of your expertise.

If you are an end user of Steam and boiler systems:

In need of a boiler service engineer, Combustion Engineer, new Water treatment? Then look no further, Steam Network UK has all the contacts you need at your finger tips.

Our website allows for individuals to search the directory for relevant services that they may require. Whether you work in Engineering, Procurement, Management or Health and Safety, you’re sure to find a member that can support your needs.

Whether you are on the look out for a new Boiler, Water treatment services or stack emissions testing, then Steam Network can put you in contact direct with a reputable business to support you and your asset base. Partnering with one of our members provides peace of mind that your assets are in the capable hands of the UK’s leading specialist in their field of expertise.

Visit www.steamnetwork.co.uk today, to find the support you need.

Please contact This email address is being protected from spambots. You need JavaScript enabled to view it. should you have any further questions.

 

• New alliance combines expertise at MC Global Solutions with Ultimo’s industry-leading¹ EAM platform across Australia, New Zealand and the UK
• MC Global Solutions’ clients to benefit from Ultimo’s holistic enterprise asset management (EAM) platform
• Facilities management (FM) and EAM expertise of MC Global Solutions to further simplify industrial asset management

More businesses in Australia, New Zealand and the UK are set to benefit from Ultimo’s Cloud-based enterprise asset management (EAM) platform thanks to a new partnership with EAM consultancy, MC Global Solutions. The company specializes in third-party software integration to automate processes, enhance efficiency and reduce costs. Working for customers such as News Corp Australia and Devro, MC Global Solutions provides an integrated set of software applications backed with superior expertise, to make business systems more efficient and effective.

Steve Martin, Managing Director of MC Global Solutions, emphasizes the importance of EAM as a strategic goal for companies aiming to optimize their maintenance and operational workflows, “Our collaboration with IFS Ultimo enhances the accessibility of asset decision-making within the EAM industry, empowering organizations to manage operations more efficiently, minimize equipment downtime, and ultimately drive improved performance.”

 

James Mansfield, Channel Sales Director at IFS Ultimo adds, “This partnership is about leveraging the strengths of both companies to bring a truly innovative solution to the markets of MC Global. By combining MC Global Solutions’ expertise in EAM and FM software consultancy with our cutting-edge platform, we are creating a solution that transforms asset management from a cumbersome process into an efficient operation.”

With 90 percent of industrial companies acknowledging that improved EAM software is pivotal to their future maintenance strategies, and only 60 percent having adopted it, the collaboration between IFS Ultimo and MC Global Solutions is an important step towards providing the tools they need.

The partnership is expected to drive significant efficiency, cost, and safety improvements for organizations navigating the rapidly evolving digital landscape.

• Facilities management use cases suggest that enhanced building maintenance efficiency, with task resolution rates increasing by 40 percent can be achieved
• For manufacturers, decreased unplanned downtime, can lead to improved machinery uptime. In some cases, the solution has sped up quality checks on more than 1,500 assets, achieving time savings of 60-70 percent
• Healthcare organizations can expect accelerated diagnostics for medical equipment.

To find out more about the joint offering, or to see the industry use cases, contact the companies here.

 

About MC Global Solutions
MC Global Solutions specializes in EAM and FM software consultancy, helping organizations streamline business processes, enhance efficiency, and reduce costs with cloud-based solutions. Learn more at MC Global Solutions.

About IFS Ultimo

IFS Ultimo, an IFS company, energizes the financial resilience, regulatory compliance and operational excellence for healthcare, manufacturing, and logistics businesses through its innovative software-as-a-service (SaaS) enterprise asset management (EAM) solutions. Focused on maintenance, uptime, safety, cost control, and efficiency, the Company is known for rapid deployment, ease of use and an unparalleled time to value. Ultimo supports over 100,000 technicians who manage more than 15 million assets for 2400+ customers worldwide. For further information see ultimo.com.

1. https://www.ultimo.com/blog/ifs-ultimo-named-an-industry-leader-in-enterprise-asset-management-eam-software-by-independent-analyst-firm/