Editorial

Leading water-lubricated and grease-free seals and bearings pioneer Thordon Bearings has appointed one of world’s most well-known propeller manufacturers as its new distributor for the UK and Ireland region.

Bruntons Propellers will represent Thordon Bearings across the countries from the 1st of January, 2024.

The propeller manufacturer will market, supply and service Thordon’s entire marine portfolio of propeller shaft bearings and seals. There is also provision for Bruntons to promote and service Thordon’s products in other market segments.

Neil McDonald, Thordon Bearings’ Regional Manager, Northern Europe & Africa, said: “We are delighted Bruntons has agreed to represent Thordon Bearings in this important geographical market. Bruntons is a well-known and established brand, with a prestigious heritage spanning more than 100 years. The company, part of the Langham Group, which includes Stone Marine and Tridan Engineering, also has the capability to machine and service bearings and seals on-site.”

A unique arrangement among Thordon’s global network of authorized distributors, it is anticipated that Bruntons will provide greater exposure across a number of market sectors in the UK and Ireland, leveraging Thordon products with major system integrators, systems suppliers, ship owners and shipyards.

Bruntons’ Director, Jonathan Shaw, explained that “the merchant maritime and defence sectors will be the main focus areas, but the agreement allows us to diversify into new industrial and pump markets. With our technical know-how and CNC machining technology, we can offer a wide range of professional sales and engineering services. We plan to have the Thordon inventory in place soon for quick turn-around delivery.”

While the UK’s defence sector has for decades been a significant proponent of water-lubricated bearings and seals due to their low noise and vibration signature, Thordon Bearings is seeing more and more UK-flagged merchant vessels look to the technology to meet existing and future environmental regulations.

“We hope soon to be in a position to announce the first order under this new agreement in coming weeks,” said McDonald. “There are a number of opportunities with new and existing customers throughout the region, since Bruntons can now offer complete propeller shaft lines with a Thordon seal and bearing package.”

A pioneer in the development of elastomer technology, Canada-headquartered Thordon has more 35 years’ experience designing, manufacturing, and installing robust, long-lasting marine bearings and seals that operate without the need for oil or grease.

The company’s marine portfolio includes the award-winning COMPAC seawater-lubricated propeller shaft bearing (the industry leader in zero environmental impact bearings); the award-winning TG100 shaft seal; the award-winning grease free deck and rudder bearing system ThorPlas-Blue; and the new and revolutionary sterntube-less propeller shaft system design, T-BOSS.

www.thordonbearings.com

Established in 1974, Truck Trye Specialists has a reputation for providing premium bead-to-bead (hot cure) and procure (cold cure) remould tyres with over 100 tread patterns to suit all relevant commercial vehicle operations. Its products are manufactured using the highest-grade rubber compounds available and have a proven track record of improving mileage, traction and fuel efficiency, equalling and even outperforming tyres from established brands.

With a five-yearly NDT inspection due on its ageing horizontal steam boiler within 18 months, and given past experiences, there was a very real prospect of it requiring major coded pressure vessel repairs again. Truck Tyre therefore needed to find a replacement solution that could cope with current and future demands, while ensuring its Net Zero commitments – already established thanks to existing recycling procedures, upgrades to facility insulation and the installation of roof-mounted PV panels – weren’t compromised.

So having discussed the requirements and researched the options with its existing steam solutions specialist, the tyre manufacturer was presented with just one realistic option, VSRT vertical steam boilers from Fulton!

Steam is used throughout Truck Tyre’s facility – including steam and waste steam via heat exchangers for domestic hot water and space heating for the facility’s offices and factory – but plays a crucial role in the vulcanisation process when moulded rubber that is extruded onto the tyre structure is placed in high-pressure curing presses or autoclaves, with steam introduced at a controlled temperature and pressure, and serving several critical functions during the process.

Firstly, steam is an excellent heat transfer medium. It transfers heat efficiently to the rubber components, causing the necessary chemical reactions for vulcanisation to occur. The heat and pressure help the sulphur atoms in the rubber chains form crosslinks, which strengthen the material. Secondly, many vulcanisation accelerators work more effectively at elevated temperatures, with heat from the steam therefore accelerating the chemical reactions between the rubber and curing agents, reducing the curing time and improving the overall process efficiency. Finally, steam ensures uniform heating throughout the company’s curing chambers and autoclaves, preventing hotspots or temperature variations that could lead to uneven vulcanisation.

In a typical five-day work week, the boiler is operational for 12 hours per day, giving Truck Tyre the ability to produce over 30,000 tyres annually using its 28 commercial presses and autoclaves. Its maximum requirement for steam peaks at approximately 1,800kg/h and the original horizontal boiler would achieve this. However, during breakdowns, regular servicing, five-yearly NDT inspections and maintenance periods, the boiler and processes using steam were all shut down. It was therefore recommended that the new system should allow for duty assist within the specification.

Two VSRT-60 steam boilers were subsequently specified, each with a rated output of 960kg/h, easily coping with demand and affording the company the ability to reduce, not completely stop, throughput during planned shutdowns.

Commenting for Truck Tyre Specialists, director Daniel Collins says: “In the 12 months prior to the installation of the two VSRT steam boilers, we were using up to 213,000kWh of gas per month during high throughput periods. However, in the six months since Fulton’s VSRTs were commissioned, we’re now using around 155,000kWh.”.

As Carl Knight, Fulton’s managing director explains, a VSRT installation has once again resulted in significant savings for the end user. “With turndown increasing from 2.5:1 to 20:1 for the installation, Truck Tyre has reported a reduction in gas consumption of nearly 30% and over 140 tonnes per year of CO₂ emissions reduced, savings that can be credited towards its Net Zero goals. Additionally, based on historical data, there has been a reduction in NOx emissions in excess of 75%.

“These alone are truly impressive, but let’s not forget savings achieved from the reduction in water usage, chemical dosing, annual inspection, five-yearly NDTs and of course process downtime haven’t been factored in, making overall financial savings compared to the original horizontal boiler installation even more impressive!”.

Applications using steam, like those at Truck Tyre, have revolutionised over the years, yet the same cannot be said for steam boilers themselves. That was until, in 2018, Fulton launched the VSRT vertical steam boiler.

Claimed to be the most radical change to vertical steam boiler design since it first pioneered the vertical tubeless boiler in 1949, Fulton’s VSRT has rocked the steam boiler market since its launch to become class-leading and a symbol of efficiency, with many users benefitting from excellent savings in gas and water consumption and reductions in CO₂ and NO_X emissions.

At launch, the seven-model VSRT range was available with outputs from 160 to 960 kg/h, but with demand increasing for an energy efficient boiler with larger outputs, Fulton has now expanded the range and introduced two new, re-designed VSRTs with outputs of 1,565 and 1,956 kg/h.

Thanks to its unique design, the VSRT’s patented spiral-rib heat exchanger virtually eliminates thermal stress, so Fulton has therefore created a longer-lasting boiler that not only improves boiler efficiency but one that the company believes will beat the competition in every category of durability. This is why all VSRTs come with the assurance of a 10-year ‘unparalleled’ warranty on the pressure vessel, double that of the industry standard.

Additionally, with features including a vertical tubeless design with no refractory whatsoever, and thanks to its industrial control platform and easy access to the pressure vessel, the VSRT is also extremely easy to maintain. As the design is tubeless, there is no requirement for five-yearly, NDTs, which contributes to reduced lifecycle costs when compared to standard horizontal boilers.

In summary, as Carl Knight explains, Fulton’s VSRT can deliver steam (at up to two tonnes per hour from single boiler) while helping with both the financial and environmental challenges that are at the forefront of mind for many decision makers.

www.fulton.co.uk

The new Contain-Air solution from FPS Air Compressors will transform the way companies gain quick and economic access to compressed air systems. As a turnkey product, the ground-breaking Contain‑Air portable compressed air room arrives on-site pre-installed and ready to use, providing unparalleled convenience, cost reductions and space savings to boost the competitiveness of UK businesses.

Adopting Contain-Air avoids the complex installation, high costs and considerable space demands associated with conventional compressed air systems. This exciting innovation overcomes these challenges by delivering a complete solution that streamlines the entire installation and commissioning process.

By integrating all components into one compact unit, the new containerised solution reduces the need for on-site assembly and minimises the risk of errors. Factories, food plants, hospitals and scientific research facilities - or any other site with a requirement for compressed air - can begin using Contain-Air immediately upon delivery thanks to connect-and-go functionality. This quiet and efficient system requires only power and connection to the air network to get started, ensuring seamless integration into existing infrastructure. Businesses can instead focus on core operations without the hassle of complex set-up procedures, knowing that they are compliant and efficient.

The complete compressed air station includes all the air treatment necessary to meet the demands of any air quality standard: industrial, food production, medical, scientific instrument, breathing air and more. As well as new installations, the system will suit companies experiencing a compressed air bottleneck or unexpected compressor downtime. The convenient Contain-Air ensures users can take advantage of resource-conserving production, process reliability and quality – in double-quick time.

Available in oil-free and lubricated formats, this compressed air cube offers working pressure of 6 to 400 bar, capacity from 1500 to 20,000 l/min and installed power from 11 to 160 kW. Notably, the compact dimensions of Contain-Air minimise the physical footprint required, which is particularly advantageous for businesses with limited space. Firms can optimise their facility layout without compromising any essential equipment.

Each self-contained unit features lighting, excellent service access, heating and ventilation. These weather-proof and extremely durable units also provide maximum security and safety for site personnel.

As a market leader in compressed air solutions, FPS Air Compressors offers innovative solutions that address evolving industry requirements. Contain-Air mirrors this commitment, delivering a product that fuses advanced technology with practicality to set a new benchmark in compressed air system convenience.

For detailed information on the new Contain-Air solution please visit:

www.fps-compressors.co.uk/contain-air

Are the compressed air leaks a problem? How much do industrial gas leaks matter? How long until worn bearings fail?

Lets explore these subjects in more detail, one at a time:-

Compressors are often situated at one end of a factory, connected to the equipment they power via pipework that typically runs through troughs or gantries, out of harms way. It is common to see multiple connections and many tee-pieces along a compressed air installation connecting pneumatic machinery and air tools along the length of a factory. It is rare for the majority of the compressed air circuit to be inspected unless there is a significant issue which is causing disruption to the production process. Afterall, if its not broke, then there is no need to fix it, right?

Similarly for industrial gasses, which are typically installed and refilled in fixed locations close to where the gas is used. These industrial gasses are connected into the production process by protected pipework that is generally ignored after the initial installation unless a significant fault arises.

While it is possible to monitor bearing health using a variety of techniques, the vast majority of bearings are ignored, especially if they are situated in difficult to access locations for example, at height, above machinery requiring production to stop in order to safely inspect their condition.

These three examples are all situations where acoustic imaging can play a role in better informing business about their equipment, both from an Energy Saving and a Preventative Maintenance perspective.

FLIR have launched the Si2 acoustic imaging camera which is able to hear the faults associated with the equipment mentioned, even within noisy operating factories when compressed air leaks, gas leaks or bearing faults are drowned out by the noise of louder production machinery.

Leaks are automatically identified and superimposed onto the 5” LCD colour screen, along with additional information such as the severity of a leak, the predicted cost to a business, or in the case of bearings, the severity of the developing bearing fault. All of this information can be reviewed on-camera, in cloud-based software, or in FLIR Thermal Studio reporting software.

So what? Air leaks are responsible for £1.4 Bn of wasted electricity consumption in the UK alone, repairing these leaks instantly lowers electricity usage associated with compressors and pumps, regaining lost margin for your production process and business profitability.

Gas leaks can be dangerous depending on the gas, but are always significantly more expensive due to the cost to purchase gasses compared to the cost of running air compressors. Repairing these leaks instantly improves the sustainability of a factory and certainly impacts the profitability immediately.

Bearings can be monitored with regular inspections, allowing replacement maintenance work to be scheduled when convenient during periodic shut-down, or addressed more urgently if needed. Most importantly, these insights into bearing condition allows the panned replacement rather than the alternative, which is responding to unexpected failures.

Two of the worst feelings are the panic when a production line stops unexpectedly, and the feeling of losing money. The FLIR Si2 is designed to alleviate both of these feelings by effortlessly identifying leaks that wate electricity and drain profits from a business, and helping to predict maintenance schedules, avoiding downtime.

FLIR offer consultations and in-person demos, with no obligation, to demonstrate the Si2 acoustic camera, allowing you to see first-hand how easy it can be to improve your manufacturing or production operation.

www.flir.co.uk

IFS, the global cloud enterprise software company, has published its most recent EAM Trend Report. The report gives a detailed overview of EAM trends based on quantitative and qualitative market research. It can be downloaded here.

As one of the most comprehensive surveys of asset management and maintenance professionals, this study gathers data from 430 asset managers across industries such as manufacturing, healthcare, energy, transportation, construction, and aerospace, and from various business sizes, including those from SMEs to large businesses. Additionally, the report includes specialist interviews with prominent industry experts, including AVEVA, Reliabilityweb.com, IFS, and IFS Ultimo.

The key findings of the IFS EAM Trend Report reflect an urgent need to enhance productivity, optimize plant conditions, and reduce downtime while aligning with sustainability objectives. At the same time, competitive market conditions necessitate strict cost controls while adhering to health, safety, and environmental protection (HSE) regulations.

Here are some of the key highlights of the report:

• There is a substantial growth opportunity for EAM solutions in the market. As 63% of respondents use an EAM solution, a significant number of 37% reported that they presently do not use any EAM solutions, indicating the rise of EAM solutions in the future.
• Most organizations aim to mature their EAM process further. Most of them state they are currently in the first three stages of the EAM Maturity Model, however, there is a strong trend to move to Stages 4 (“Smart”) and 5 (“Ultimate”) by implementing Predictive Analytics (56%) and Long-Term Asset Planning and Asset Investment Planning (50%).
• Asset Performance Management (APM) is on the rise. 57% of asset managers expressed a strong interest in exploring the potential of APM technologies to enhance the health and performance of their vital assets, leading to improved efficiency and decision-making.
• Emerging technologies will positively impact maintenance and business practices. The top 3 emerging technologies to gain competitive advantage are Internet of Things (IoT) sensors, predictive modeling, and artificial intelligence (AI) while key obstacles are a need for more experience and costs.
• 3 topics that shape the future of EAM are prioritizing better use of reporting and analytics (61%), increasing digitalization (44%), and investing in retaining or attracting suitable maintenance personnel (38%).

Ewout Noordermeer, CMO, IFS Ultimo said “For us, this study provides valuable insights for the further development of our products. Most of all, we hope it will inspire professionals in maintenance and asset management.

“The outcomes of the study show that different use cases ask for different solutions. Since the acquisition of IFS Ultimo in 2022, IFS is the only vendor in the world that offers both “best-of-suite” EAM (IFS Cloud EAM) and “best-of-breed” EAM (IFS Ultimo). IFS Cloud EAM is the perfect match if you are looking for a composable solution that goes beyond EAM, including service management, APM, and ERP capabilities. IFS Ultimo is ideal if you want a pure-play EAM SaaS solution with a fast time to value,” Noordermeer concluded.

The IFS Trend Report can be downloaded via this link:

IFS launches EAM Trend Report - IFS Ultimo

Birmingham, UK | January 30, 2024 | The expansion of renewable energies is being driven to a great extent by wind turbines. Wind turbines are becoming larger and more powerful. The main shaft bearing system, as an integral part of the drive train, is of elementary importance, as this is where all the forces and torques exerted by the wind on the turbine add up. As a market leader and strategic development partner, Schaeffler is rising to the challenge and will contribute actively to the development of multi-megawatt wind turbines.

In Lindø, Denmark, the world’s most powerful test facility for main shaft bearings will be built at LORC (Lindø Offshore Renewables Centre). The investment is in the mid-double-digit millions and includes grants from the Danish GreenLab programme. Concrete test programmes should already be running by the end of 2025. LORC has partnered with R&D Test Systems, which is one of the leading suppliers of test benches for the wind industry, to build the new test facility. Schaeffler played a major part in defining the specifications of the test facility and will be the first customer to test its main shaft bearings for future generations of wind turbines in cooperation with OEMs.

Dr. Michael Pausch, CTO Industrial Schaeffler, stresses: “We are a key market and technology leader for bearing technologies in the wind power industry. With LORC, one of the most experienced operators of test facilities for wind turbine drivetrains, we have found a partner to help us further expand our know-how and our product performance. We now have the opportunity to shape the development of the next generations of wind turbines with suitable testing technology and method development.”

“We have been gaining valuable insights for the development of bearing solutions since 2011 with our large-size bearing test bench 'Astraios,’ the world’s most powerful test bench at the time. With the new test facility, we will now be able to advance into new and future dimensions and contribute to a more rapid development of reliable multi-megawatt turbines,” adds Bernd Endres, Vice President Business Unit Wind, Schaeffler Industrial. 

“Closed loop engineering” for wind turbine bearings
Schaeffler has been offering reliable bearing solutions for on- and offshore wind turbines for around 40 years. Rolling bearings from Schaeffler are found in every second to third wind turbine worldwide. 

Schaeffler takes a “closed loop engineering” approach for its wind turbine bearings. Besides engaging in the pure development of bearing solutions, the Schaeffler experts also support turbine development with system simulations, testing, and field measurement campaigns. The findings gained flow back into the further development of customers’ projects, design tools as well as the development of new bearing solutions. The experts from Schaeffler work closely with developers from OEMs to increase the reliability of wind turbines and make wind power more cost-effective. The new test bench will provide an important building block for the developments of the coming decades.

QR Connect, a SaaS specialist in improving service processes, and IFS Ultimo, leading cloud-based Enterprise Asset Management (EAM) software provider, today announced a new partnership that enables mutual product integration. This collaboration combines the power of QR Connect's innovative platform with the advanced capabilities of IFS Ultimo's EAM software.

Streamlining incident mobile reporting with improved User Experience (UX)

Through this partnership, IFS Ultimo provides organizations with a more efficient and streamlined process for mobile reporting of incidents and maintenance tasks. The integration between QR Connect and IFS Ultimo not only offers a user-friendly platform, but also contributes to further optimization of operational processes within organizations.

Merlijn de Vroe, Owner, QR Connect, commented on the collaboration: “This integration makes it easy for users to quickly access the right information without needing an app. The process of mobile reporting is also much faster, enabling organizations to respond more effectively.”

Patrick Beekman, Partner Manager, IFS Ultimo, shared: “QR Connect’s solution is a valuable addition to our offering. The mobile reporting of incidents or issues is now easier than ever and can be done directly on site. More details and service possibilities are available on the IFS Ultimo Marketplace.”

Benefits to customers

Through this collaboration, QR Connect and IFS Ultimo customers have access to an innovative solution that meets the ever-growing and changing needs of organizations. The key benefits of this new partnership include:

• Swift reporting: Users can quickly and easily report incidents with a single scan of a QR code, saving valuable time for both the user and the helpdesk.
• Improved efficiency: The integration streamlines processes, resulting in more efficient asset management and a faster response to incidents.
• Real-time communication: Teams have the ability to communicate in real-time, promoting collaboration and accelerating decision-making.
• Quality asset management: Organizations benefit from enhanced asset management, with assets being accurately tracked.
• No app required: Users can report issues and access manuals on their mobile phones without the need to install an additional app.

As of 2024, the entire popular and high-performing Tundra range of refrigerant air dryers from Hi-line Industries will transition to R-513A, a refrigerant with zero ozone depleting potential (ODP) that helps customers to enhance their sustainability credentials. Although Hi-line attributes the success of the Tundra range in compressed air applications to its ultra-reliable performance, energy efficiency and reasonable price tag, the introduction of R513-A and its zero ODP means there really is no need to go anywhere else for refrigerant air dryers.

R-513A (Opteon™ XP10) refrigerant is a hydrofluoroolefin (HFO) based replacement for R-134a. Ideal for use in medium and low temperature refrigeration products, such as Tundra air dryers, R-513A offers 56% lower GWP (global warming potential) than R-134a, delivering long-term sustainability and F gas legislation compliance.

Notably, R-513A resides in the A1 (non-flammable) safety class, making it an ideal retrofit candidate for R-134a, while offering very similar cooling performance. R-513A also provides negligible temperature glide to ensure reliable performance day after day.

Despite the new innovation in refrigerant development, Hi-line intends to hold pricing for the Tundra range firm throughout 2024. This initiative will help customers combat challenging trading conditions and remain competitive in their respective industries.

Tundra refrigeration air dryers are in widespread use across UK industry, improving the quality of compressed air, protecting valuable assets, and outperforming rival technologies in energy efficiency by minimising pressure drop and lowering absorbed power. Among further features driving Tundra’s energy-efficient characteristics is a patented single-cell heat exchanger, which delivers highly efficient heat transfer at low energy costs, and a link between the controller and condensate removal valve for minimum loss of compressed air during condensate discharge. To indicate the regard held for Tundra as a value-added solution for companies running compressed air systems, this innovative product recently gained recognition at the prestigious iPlex Awards, in the ‘Energy Management Innovation’ category.

Indeed, the acknowledgement of Hi-line’s impact on industry stretches far beyond Tundra refrigeration air dryers, with Managing Director Steve Smith’s recent induction into the Industrial Plant and Equipment Hall of Fame a case in point. Steve Smith has a depth of experience in the compressed air sector that spans over 40 years. In particular, the judges praised his commitment to corporate social responsibility, whether it is his willingness to take the lead on charity initiatives, or Hi-line’s sponsorship of local sporting teams. On this note, the company will continue to sponsor Tom Hamer, defender at League One football club Burton Albion, throughout the 2023/24 season.

Hi-line are also sponsors of Burton Rugby Football Club – First Team with the logo on the chest of all the First Team Shirts. Along with the sponsorship of the Hi-line Moto X team, this year Hi-line’s sponsorship is extend further by sponsoring Help for Heroes to enable the rehabilitation of war veterans to travel pillion on a motor cycle along Route 66.

Further information is available from: Hi-line Industries Ltd,

Green Street, Burton on Trent, Staffordshire  DE14 3RT

Telephone: 01283 533377                                           Fax: 01283 533367              

e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.                      www.hilineindustries.com

For openpack, the partnership with IFS Ultimo means an expansion of its integrated partner portfolio which results in adding extra value for its customers through additional features. This is seen through simplified commissioning, reduced IT effort as fewer interfaces are required, and optimized maintenance software.

IFS Ultimo also expands its partner ecosystem of industry leaders through this partnership. Together, both companies already have several joint manufacturing customers in the packaging industry. The knowledge that they have built together in this industry is now being used to support other companies in this sector.

Patrick Beekman, Partner Solution Manager at IFS Ultimo, commented: “The platform approach of openpack allows us to work seamlessly together. By joining forces, we enable an efficient reduction of interfaces and simplified data provision, allowing end customers to easily integrate and use IFS Ultimo's solutions via the openpack platform. We are looking forward to supporting customers together through our joint offering and joint knowledge.”

Patrick Klee, Chief Product Officer at openpack, added: “The decision to enter this cooperation is based on a shared vision and understanding of the changing requirements in the packaging industry. We share a clear commitment to digitalization and recognize the importance of innovative solutions for the future. 
The synergy between us lies not only in our shared industry, but also in the strategic alignment of our offerings. Both companies' complementary products and services create real added value for our customers. This partnership enables us to strengthen our solutions and tailor them optimally to the needs of our customers.”

Following an extensive upgrade of its reception tank and digester mixing system, Eco Verde Energy (EVE) has put a once troublesome Anaerobic Digestion (AD)+ plant firmly back on track with encouraging new biogas yields.

At Holton* in Suffolk, England, which receives around 65% of its feedstock from the adjacent Bernard Matthews poultry facility, the AD plant, under a series of different operators, had seen biogas production drop significantly, and eventually to a complete halt for a much-needed overhaul.

Initially, the primary digester (2700m³) was drained down, discovering, as expected, faults with the mixers, but also a broken stanchion. Later, further inspections revealed that there was damage to the roof of the digester, so the decision was taken to postpone operations for a complete maintenance revamp.

“The mixers that were sold in as part of the biogas package were never going to last in the long-term,” said Eco Verde’s Site Manager at Holton, Kris Martin.

“It is hard to understand a design that doesn’t allow equipment to be looked after! The mixers couldn’t be lifted out of the tank for even the most basic of service tasks such as an oil change and cleaning the propellers.”

He added: “At one point, the site was being run remotely, but it has now benefitted from a complete review of operations. When we shut down for the maintenance overhaul, trying to get shipshape became more challenging, due to some suppliers not being able to assist; either unable to provide equipment quick enough for our needs, or did not seem to have a deep understanding of the industry. Either way, the essential assistance we required was not readily available. We couldn’t for example, get anyone to look at the feed-in module (which is a jacketed tank to provide heat) we have between the reception tank and the digesters. The previous chopping pump had failed because of the high temperatures, so again, it wasn’t specified properly. There can be a huge difference in supplying equipment in 304 stainless steel compared to 316. For a biogas process with food waste, compromising is only going to lead to problems.  This has been the classic case of a package plant being sold on price rather than quality.”

Matters took a significant turn for the better though when Kris made contact with Landia, about whom he’d heard good reports.

‘Clearly wanted to try and understand how a solution could be found’

He continued: “They’re a pump and mixer company, and there are plenty of those,” he said, “but unlike some others, they actually listened and clearly wanted to try and understand how a solution could be found. As soon as they first came to the site, there was a good vibe. Linking up the mixing operation from the reception tank, through the feeding module, and then on to the digesters, and finally through to the pasteurisers, wasn’t going to be easy, but rather than just try and sell us equipment, Landia were keen to find a way to help make the Holton plant perform as it should.”

New submersible mixers (5.5kW) from Landia have been installed for the reception tank, which unlike the previous units, can be easily lifted up on a crimped rail system for inspection to remove any plastics and perform standard maintenance such as oil changes.

For the feeding module, which is batch-fed from the reception tank, a Landia Chopper Pump (invented by the company in 1950) has replaced the failed unit. The unique external knife system (combined with the addition of a new shredder propeller) ensures that particles are continuously reduced in size, and that solids cannot enter the pump’s casing.

The primary digester was first upgraded to replace the failed units with Landia mixers. By utilising a pre-existing hatch system that provides easy access, these new 18.5kW mixers were installed with minimal disruption to the biogas process, and can likewise be easily serviced without causing downtime.

The secondary digester is now served with a system that comprises the proven Landia chopper pump, fitted with venturi nozzles to provide truly comprehensive mixing. When the primary digester meets the right level, the feedstock is automatically transferred to the secondary digester. The simple, but highly effective combination of submersible mixers, chopper pumps, and the venturi nozzles work to constantly recirculate the mixture of liquid and gas, even though it only typically has to run in 10-minute intervals, rather than mixers at many plants that run flat-out 24/7.

At the end of the process, in order to meet the legal requirements of a feedstock that contains animal bi-products, there are now two (25m³) Landia pasteuisers, which heat the final effluent to the required temperature of 70 degrees centigrade. The pasteurisers are supplied as complete processing units (tank, chopper pump, and controls), to break down the food waste effluent and any remaining solids. Each tank from Landia is made with a double stainless-steel tank wall that acts as a heating jacket. From here, heat is transferred by circulating hot water, meaning that a heat exchanger is not always required. Post-pasteurisation, with the maximum possible amount of gas extracted, the final digestate from Holton makes a first-class, nutrient-rich fertiliser.

‘Nothing on this site is now off-the-shelf’

Kris Martin added: “The more Landia and I worked together, the more we had a focal point. Although they do provide some guide rails and pipework, it’s not their main business, but when looking at how we could transfer everything from the start of the process, right through to the pasteurisers, it made sense for Landia to include it as part of their service, rather than me having to bring in another supplier. They did a top-quality job in putting all the extensive pipework together. It’s very impressive and we’re all proud of it. Nothing on this site is now off-the-shelf. Paul Broadhurst (from Landia) and I have put this all together step-by-step. It’s not been easy, but we’ve worked through it with a very healthy rapport and that all-important common goal of wanting something to work and work well for the long-term. It’s a world away from the daily hassles that we had previously. Paul’s attitude to whatever we ask is ‘we’ll sort it out’, and I know he and Landia will, because they value us as a customer and care about the plant’s success.”

In addition to its primary feed (which is first treated by a DAF -Dissolved Air Flotation) piped in from the Bernard Matthews poultry facility’s treatment plant, EVE’s Holton site also receives effluent from the local Adnams brewery and distillery, plus various fats and oils from nearby food processing plants. This variety of intake then takes very careful managing to maintain a steady feed for the now, much loved biogas plant.

Kris Martin continued: “With the Landia submersible mixers at the front end, we’ve gradually developed a constant, homogenous feed, which provides excellent stability for the remainder of the process and our drive to maximise biogas yields. The consistency we have means happy bugs, because otherwise, too much of one intake at one time can cause foaming. That’s not an issue at this site any more.”

At 1.1MW, the new-look Holton biogas plant (which now has two CHP engines and additional gas storage), can provide most of Bernard Matthews' 1.4MW energy needs, with a grid connection in place for times if/when the poultry facility is on shutdown.

‘Low energy consumption

and maximum biogas yields’

Kris commented: “The investment here safeguards the future, with plans for a lagoon to be built and to have PAS 110. With Landia’s help, it means that we’ll be in good shape with low maintenance costs, low energy consumption and maximum biogas yields, which of course means profit – not to mention the fact that we do something great by making renewable energy from waste.

“Having to shutdown and clean out a couple of digesters creates downtime of almost three weeks; costing in the region of £150,000. We’re pleased of course to have now sorted out all the problems; turning everything around so that instead of having put out fires, we can finally be proactive and concentrate on making gas, rather than having to react to all the problems on site. The initial issues were made all the worse by having equipment that you couldn’t work on without having to shut the plant down! A design that effectively traps mixers inside the tank without access is ridiculous.

“We now have a proper maintenance schedule in place, and unlike in the past, no problems or delays in the availability and delivery of parts. If we order before lunchtime, Landia deliver the next day. During installation, there were also never any problems with the paperwork and permits from Landia; progress emails, and all the necessary RAMS (risk assessment and method statement) and proof of qualification were in place so that the work was seamless, with no delays. This differs significantly from others who simply aim to provide a product, without considering how it integrates into our process.

“Site managers can overcome all sorts of challenges, but aren’t necessarily engineers. You need calculations. You need experts to answer your questions to complete the jigsaw puzzle. No two plants are the same. It is reasonable to expect seamless support from the companies that provide equipment, but often, you find yourself navigating through various departments – from quotations to finance, engineers, and a loosely termed ‘support team.’  Having to repeatedly explain your requirements can be very frustrating and time-consuming. It is always easier to work with those who have been to a biogas plant, and who aren’t worried about getting their hands dirty. It’s been a long journey to get where we are, but we now have peace of mind with a plant that is performing very well and with fine-tuning, will get even better. It shows exactly what can be achieved with the right people, the right equipment, and a belief in our industry.”