Latest Case Studies & White Papers

• Incorrect mounting and dismounting of rolling bearings, as well as imbalances in machine shafts, can result in damage to the bearings and other components
• Schaeffler’s new white paper provides all you need to know about the correct preparation, installation and removal of rolling bearings, and how to ensure machine shafts are properly aligned.
• The paper includes basic knowledge, expert tips and guidance, as well as case studies showing how customers are profiting from using the right tools for the job.

Birmingham, UK | August 6, 2024 | Global motion technology company Schaeffler has published a white paper on the mounting and dismounting of rolling bearings and shaft alignment.

Learn from the experts on how to avoid damage during bearing mounting and dismounting, how to simplify mounting work, how to save time and ultimately money by protecting the bearing and optimally aligning your machines. Schaeffler’s practical white paper contains valuable knowledge that you can incorporate directly into your maintenance process.

Our 10-point checklist for safe mounting work will help you avoid premature bearing failures in the future:
    

• Protect your workspace and the rolling bearing from dust, dirt, and moisture.  
• Use drawings to familiarise yourself with the design.  
• Make sure that your bearing matches the specifications on the drawing.  
• Check the housing bore and the shaft seat for dimensional, shape and positional accuracy, as well as cleanliness.  
• Ensure that the mounting of the bearing rings on the shaft or in the housing bore cannot be impaired by edges. A slip angle of 10° to 15° is helpful.  
• Wipe off any corrosion protection on the seat and contact surfaces.  
• Apply a very thin layer of suitable mounting paste to the cylindrical seating surfaces of the bearing rings.   
• Do not cool the bearings. Condensation can lead to corrosion in the bearings and bearing seats. 
• After installation, apply a suitable lubricant to the rolling bearings.   
• Check the bearing to make sure it’s working properly.

These are just a few of the basic recommendations, though to explore further and delve into things like which tool is suitable for certain bearing or bore types, Download the White Paper here.

An underground oil pipeline at a Refinery in Spain was suffering from severe corrosion. If left unchecked, the pipeline, 872 metres (2860.8 ft) in length, would have incurred severe metal loss. As a result, disastrous consequences, both financially and also from an environmental perspective, would have ensued.

Figure 1. Corroded pipeline restored with composite wrap

Solution Sought to Mitigate Cost and Carbon Footprint of Pipeline Replacement   

A prompt repair was required for the carbon steel pipeline, 55.9 cm (22 inches) in diameter, in order to mitigate any further corrosion damage being incurred. In fact, if left unchecked, this would have caused the substrate to completely corrode through and, therefore, serious environmental issues would have ensued.  

A potential solution would have been to completely replace the pipeline. However, considering its mammoth length, this process would have required considerable financial expenditure and, furthermore, would incur a hefty carbon footprint.

For every ton of steel that is produced, 1.85 tons of CO₂ - nearly double the amount - is released back into the atmosphere (Carbon Clean). In addition to this, the process of removing and disposing of the damaged pipeline further ratchets up the carbon footprint of this process.

As well as the environmental impact of replacing the corroded pipeline, this process would also require a considerable period of downtime which would lead to further profit-loss. The combination of these factors, costly in both a financial and environmental sense, led the Customer to seek out an alternative solution to replacing the steel pipeline.  

Expensive Replacement Process Bypassed with Composite Wrap

The Customer decided to repair and protect the pipeline with a combination of polymeric technology in order to bypass the drawbacks associated with replacing the pipeline.

The following systems were specified and applied following an inspection from Elena Expósito Fernández, AMPP (NACE) Certified Coating Inspector Level 2 and Technical-Commercial Delegate at authorised Belzona Distributorship Rodator Composites:  

“The 2-part epoxy paste, Belzona 1111 (Super Metal), was specified to fill in any gaps in the weld seams to ensure the pipeline had a smooth profile. For heavily corroded areas, plate bonding was required using steel plates which were 50 cm x 60 cm (19.9 in x 23.6 in) in size, with a thickness of 5 mm (0.2 in). These were bonded into place using the epoxy structural adhesive, Belzona 7311. To reinforce the pipeline, the composite wrap, Belzona SuperWrap II, was specified. Finally, the anti-corrosion coating, Belzona 5811 (Immersion Grade), was chosen to provide long-term corrosion protection.”   

Figure 2. Elena Expósito Fernández, Technical-Commercial Delegate at Rodator Composites

Figure 3. Application of composite wrap, Belzona SuperWrap II, to the steel pipeline

Figure 4. Anti-corrosion coating, Belzona 5811 (Immersion Grade), applied to pipeline

Polymeric Technology Supports Decarbonisation of Oil and Gas Industry    

The Customer was able to successfully bypass the drawbacks associated with complete pipeline replacement by instead, opting to repair and protect the pipeline with a combination of polymeric technology. As well as making huge financial savings, this solution enabled the Customer to also minimise its environmental impact as well.

As the oil and gas industry continues to decarbonise, this latter point is particularly paramount. Polymeric technology is an extremely viable way in which oil and gas asset managers can make great strides in mitigating the carbon footprint of their facilities. An increased uptake in the use of cold-applied repair composites and protective coatings would help to accelerate the decarbonisation of this industry.

For more information, visit: www.belzona.com

On May 8^th, 2024, the historic Ship the Belem navigated into the bustling port city of Marseille, marking the arrival of the Olympic torch in France. Over 150,000 spectators gathered to witness as the Ship sailed into the bay, accompanied by over a thousand boats. Last year, Alliatech, one of Belzona’s French distributors, was involved in the restoration of this historical Ship.

At a chitosan production plant in Scotland, UK, a high-performance, anti-corrosion coating was used to coat the internal lining of three tanks, protecting them against aggressive, acidic substances for the long term. Given the important role the tanks play in the process of turning large amounts of shellfish byproduct into the biopolymer chitosan, it was imperative that these assets were safeguarded against future damage with the use of a high-performance coating.

Figure 1. High-performance coating required to protect tanks against corrosion

Production of Biopolymer from Shellfish Shell Byproduct

CuanTec has created a circular economic business model designed to mitigate the carbon footprint created from the unnecessary disposal of unused shell within the shellfish industry and converting it into valuable chitosan products.

Indeed, the carbon footprint of food waste is staggering. According to data from the UN, food waste contributes to 8% of global greenhouse gas emissions. This means that if food waste was a country, it would be the third-largest emitting country in the world.

At COP28, negotiators from 200 Parties agreed on the science from the Intergovernmental Panel on Climate Change (IPCC) that global greenhouse gas emissions need to ‘be reduced by 43% by 2030’, in order to limit warming to 1.5°C (2.7°F) by 2050, in line with the Paris Agreement. With this in mind, circular business models such as that offered by CuanTec, play an important role in mitigating carbon footprints and limiting global warming to 1.5°C (2.7°F).

Safeguarding Key Assets

Considering the important role businesses such as CuanTec play in this decarbonisation and upcycling journey, it is absolutely fundamental that key assets within these types of businesses, such as machinery, equipment, buildings and structures, are safeguarded to an excellent standard. Otherwise, damage and wear can jeopardise the integrity of assets, and therefore this can undermine the environmental benefits these types of business models offer.

For example, the carbon footprint of steel is phenomenal: for every tonne of steel produced, nearly double the amount of carbon dioxide (CO₂) is released back into the atmosphere. Therefore, if a steel asset becomes damaged, not only can this lead to costly replacement fees, but this process can also incur a hefty carbon footprint as well.

As such, numerous industries invest in industrial repair composites and high-performance coatings in order to bypass this replacement process. In this way, polymeric technology mirrors the circular economic model of businesses like CuanTec, as this technology can repair, protect and even intrinsically improve assets that would otherwise be decommissioned and sent to landfill. Thus, it could be argued that polymeric technology has a critical part to play in the decarbonisation of multiple sectors, supporting a net zero by 2050 pathway.  

Pre-Used Tanks in Need of Rigorous Corrosion Mitigation Measures  

CuanTec wanted to deploy three steel tanks in their process of turning shellfish shell into high quality, traceable chitosan products, made to the exacting technical specifications of their customers. The tanks had already been in use elsewhere, but were otherwise still in good condition. In order to ensure the tanks were capable of withstanding the harsh chemicals they would come into contact with, the Customer decided to invest in some polymeric technology to protect them.

System Specification: High Performance Coating, Belzona 1391T

Following an inspection from Clive Leadbitter, Senior Field Sales Engineer at authorised Belzona Distributorship, Belzona UK, the high-performance coating, Belzona 1391T, was specified. As this system is capable of protecting assets against corrosion in extremely aggressive and acidic environments, this was the ideal solution for the steel substrate for this specific application.

In addition, as Belzona 1391T can be applied in situ without the need for hot work, this would ensure that the application was carried out as quickly as possible, whilst minimising the health and safety risks that can arise when hot work is involved.

Belzona 1391T has undergone direct food contact (FDA) testing, the results can be found here.

Figure 2. Tank used in process of creating biopolymer, chitosan

Application Procedure

Commenting on the application procedure, Clive said: “Surface preparation was carried out by grit-blasting. Following this, using a stiff-bristled brush, two coats of Belzona 1391T were applied at a thickness of 450 µm (17.72 mil) per coat. Once the application had cured within the space of 24 hours, the application was complete.”

Figure 3. Application of high-performance coating, Belzona 1391T

Polymeric Technology Supports Net Zero by 2050 Pathway

Considering the important role businesses like CuanTec play in carbon mitigation, it is absolutely critical that key assets are protected for the long term against damage such as erosion and corrosion. As such, polymeric technology plays an important part in safeguarding these assets, and therefore contributing to the net zero by 2050 pathway.  

www.belzona.co.uk

Introduction:

In the pursuit of maintaining high standards of safety in the food and drink Industry Belzona is constantly seeking innovative solutions to address challenges related to equipment maintenance and corrosion protection. Recently, after undergoing rigorous tests to ensure its suitability for dry food contact, a breakthrough has been achieved with the successful application of Belzona 5811DW2 (DW Immersion Grade), a cutting-edge protection system, in a Flour Mill in Belgium.

Understanding the Need for Food-Safe Coatings:

The food and drink industry is bound by strict regulations and guidelines to ensure the safety and quality of products. Food comes into contact with many materials and articles during its production, processing, storage, preparation and serving, before its eventual consumption. The European Food Safety Authority state that Food Contact Materials (FCMs) should be sufficiently inert so that their constituents neither adversely affect consumer health nor influence the quality of the food.

Flour mills, being a crucial part of the food supply chain, must adhere to these standards. Equipment used in the milling process, such as storage tanks, hoppers, chutes, and conveyors, is prone to wear, corrosion, and degradation over time. Traditional coating solutions often fall short in providing a long-lasting, food-safe barrier.

What is the EU Food Regulation 10 2011?

EU food contact legislation covers the general rules applicable to all materials and articles intended to come into contact with foodstuffs (Regulation (EC) No. 1935/2004). For specific materials such as plastics, more detailed legislation has been additionally in place for several years.

Regulation (EU) 10/2011 sets out safety requirements for plastic materials and articles intended to co­­­­me into contact with food. This regulation is a specific measure for plastic food contact materials as mentioned in the European Framework Regulation (EU) 1935/2004.

This Regulation applies not only to plastics food contact packaging but to equipment such as food storage tanks, pipes, pumps, containers, conveyer belts, etc.

Belzona 5811DWII (DW Immersion Grade) Approved for use on Large Storage Tank at a Flour Mill

Belzona 5811DW2 (DW Immersion Grade) is a solvent-free coating initially designed for the protection of surfaces operating under potable water immersion or where potable water approval is required.

Reacting to customer demand, Belzona Distributor; Perspect Benelux recently invested in comprehensive testing to evaluate the coating’s suitability for contact with dry foodstuffs.

Their customer, a large Mill in Belgium who specialise in the production and development of physically treated wheat flour and mixes used as cake flour, sought a coating suitable for contact with flour which would provide long term corrosion protection. Building on the success of achieving WRAS approval for contact with drinking water, Belzona 5811DW2 (DW Immersion Grade) was put forward as a possible solution.

Comprehensive Testing:

Confident in the performance of the Belzona, Perspect Benelux opted to have Belzona 5811DW2 (DW Immersion Grade) tested by the Belgian packaging institute; IBE-BVI, who are an accredited independent laboratory according to ISO 17025, recognised throughout Europe. Their results confirmed the coating’s compliance with specific requirements of European Regulations No. 1935/2004 and No 10/2011 for prolonged contact with dry foodstuffs.

Perspect Benelux was able to provide tailored support to the customer, in collaboration with Belzona, by providing sufficient data and evidence to satisfy the customer that Belzona 5811DW2 (DW Immersion Grade) is safe and suitable for their specific needs and service conditions.

The positive results were recognised on completion of the project, by the FAVV (Federal Agency for the Safety of the Food Chain) who confirmed application was completed according to the approved method, using Belzona 5811DW2 (DW Immersion Grade).

The unique formulation of this Belzona coating not only ensures compliance with food safety regulations but also offers outstanding protection against corrosion and abrasion. It has been certified as non-leaching, with no harmful emissions or influences on dry food products and flour based on this customer’s specification.

This future-proof coating was also found to conform to the maximum limits of mineral oil aromatic hydrocarbons (MOAH), mineral oil saturated hydrocarbons (MOSH) and Polyolefin oligomeric saturated hydrocarbons (POSH).

The likelihood of these guidelines becoming a requirement in the near future is significant due to the new EU Food standards coming in place.

The results of the tests were not only promising but exceeded expectations, leading to the green light for the application to the internals of a 6000 sq. metres (7175.94 sq. yards) in total flour storage tank of 30 tanks.

Original tank substate

Due to the age of the installation, the original lining was blistering and there was a risk it could contaminate the product to be stored in the tanks. In order for the customer to re-use these old, out of service tanks, a new lining was required. Other linings were tested, however Belzona 5811DW2 (DW Immersion Grade) was the only one approved by the QA-QC department. The alternative would have been to build a new silo complex which would have been extremely expensive.

Application Process:

The application of Belzona 5811DW2 (DW Immersion Grade) in the Flour Mill followed a meticulous process to ensure long-lasting protection. The steel surfaces of the tank to be coated were prepared, cleaned, and blasted to the recommended standard of cleanliness, Swedish Standard Sa 2½, SSPC-SP10 (Near-White Metal) with a minimum profile of 3 mils (75 microns). Two coats were then applied by airless spray in cream, to a Dry Film Thickness of 400µm (15.75 mil).

The marine industry plays an essential role in steering the course of global commerce the total value of the annual world shipping trade has reached more than $14 trillion (US dollars). According to the United Nations (UN), a staggering 90% of everything we consume is transported by sea. Given the colossal size of the marine industry, it is essential to implement a range of strategies to enhance its sustainability. For example, it is imperative to discover a more sustainable fuel source, and finding solutions that enhance energy efficiency will be crucial.

Of these strategies, advanced coatings and repair composites play a significant role, offering not only the promise of efficiency gains and cost savings but also a seamless alignment with the broader goals of the Blue Economy. The UN iterates that the Blue Economy should “promote economic growth [...], while at the same time ensuring environmental sustainability of the oceans and coastal areas”. By simultaneously reducing costs and fortifying assets, these solutions, such as those produced by Belzona, echo these Blue Economy principles, steering the marine industry towards a more sustainable future.

Boats new and old repaired and protected with Belzona

What is the Environmental Impact of the Marine Industry?

Climate Action Tracker reports that the maritime sector presently accounts for about 3% of all global greenhouse gas (GHG) emissions. If left unregulated, projections suggest that this figure could surge to 17% by 2050. Thus, there is a pressing need for measures to curb and limit this escalation. Surprisingly, Brazil, the 5^th largest country in the world, emits just 2.44%, underscoring the maritime sector's outsized role in global emissions.

To contextualise this further, marine transportation far surpasses both the carbon and total greenhouse gas emissions of international aviation. While aviation, a major emitter, contributes about 600 million tonnes of CO2 (MtCO2) per year, marine transport creates a huge 940 MtCO2 annually. Notably, the maritime industry also emits more than twice the amount of total greenhouse gas.

These statistics reveal the mammoth role of shipping in global emissions compared to other industries. Comprehensive measures are urgently needed to address and mitigate the environmental impact of the marine industry in the pursuit of sustainable practices.

What Strategies Are Being Implemented to Address This?

In recent years, a number of new regulations have been created to reduce and prevent air pollution created by shipping. For example, Annex VI of the MARPOL treaty, set in place by the International Maritime Organization's (IMO) limits the sulphur content of marine fuels and regulates emissions of NOx. 

A chapter of this treaty added in 2011 targets operational energy efficiency measures with the goal of diminishing greenhouse gas emissions. There is a growing emphasis on adopting cleaner alternative fuels, improving energy efficiency, and hull design modifications, to reduce the carbon footprint of the industry. In addition, steps are now being taken to minimise the impact of heavy shipping on sea life. Let's take a look at some of these strategies in more detail:

Efficiency restored with Belzona for bow thruster of private yacht

The Marine Fuel Dilemma

In the pursuit of environmentally sustainable alternatives to Heavy Fuel Oil (HFO) and Marine Gas Oil (MGO), various options, such as LNG, hydrogen, ammonia and methanol, have been explored - each with its own set of challenges.

Liquefied Natural Gas (LNG) has grown in popularity in recent years; however, it is not a viable alternative as switching to LNG would not create a reduction in total GHG emissions. Although LNG has a lower carbon content, it raises methane emissions, which are 80 times more potent than CO2. In fact, the International Council on Clean Transportation (ICCT), asserts that using LNG as a marine fuel emits over 120% more life cycle GHG emissions than MGO. It therefore must be acknowledged that LNG, despite its lower carbon content, remains a high-emission fossil fuel and falls short as a sustainable alternative.

Sustainably produced hydrogen, ammonia and methanol, when produced from renewable sources, are all good sustainable options but face challenges in availability, storage and flashpoint. For example, Hydrogen encounters storage challenges due to volume. Furthermore, most hydrogen produced today is grey hydrogen (not produced sustainably). If enough green hydrogen could be produced and stored it would make a great sustainable alternative. Ammonia boasts easier storage characteristics but would also need to be produced in a carbon-neutral manner and has a low flash point. Provided a sufficient quantity could be produced, green hydrogen, green ammonia or green methanol offer sustainable options. As the industry grapples with the marine fuel dilemma, it becomes evident that more work is required to find a truly sustainable solution to this complex problem.

Historical and projected transport demand and GHG emissions from international Shipping| Source: UNEP, World Bank

Marine Cavitation

Thinking beyond greenhouse gas, the blue economy faces a host of other environmental concerns, including underwater noise pollution. Propeller cavitation leads to excess fuel consumption and can generate as much as 180 decibels of underwater radiated noise (URN) which can be heard by marine life over 100 miles away.

Propeller-induced cavitation is the formation and rapid collapse of bubbles, and this is the main source of underwater sound produced by ships. In fact, the propellor is responsible for about 80% of a ship's URN. The EU has already put in place thresholds to cut down on underwater noise and the IMO issued guidelines last year too. The UN has 17 Sustainable Development Goals and Goal 14, Life Below Water addresses the need to protect marine life. A recent study by the University of Victoria showed how beluga whales avoid marine noise even when many miles away as it masks their vocalisations. This can lead to chronic stress and the animals being displaced from their habitat. Reducing underwater noise footprint will help with species conservation.

Cavitation damage also reduces the propulsion efficiency of a propeller, incurring economic loss due to excessive fuel consumption and the requirements of frequent maintenance. It is clear then a long-term solution for propellor cavitation is required.

Case Study

One solution to reduce propellor cavitation, is to repair and protect cavitated propellers with Belzona. In the example below, Belzona 1111 (Super Metal) was used to build up the worst affected areas and then Belzona 1341 (Supermetalglide) was brush applied to provide overall protection. The customer opted for this solution after the failure of welding and inferior coatings. In a study carried out by Leeds University, it was found that Belzona 1341 (Supermetalglide) was fifteen times smoother than polished stainless steel, making it ideal for reducing resistance and noise as well as increasing efficiency. The port now has the confidence to inspect on a less frequent basis meaning the vessel can survey the river for longer periods, saving time and money in a dry dock.

After 10 years of service the hull of the vessel was suffering from cavitation around the propellor area. 

Engine Chocking

As well as repairing and protecting propellors from cavitation, engine chocking to reduce vibrations is key for noise reduction and safety. The essential role of engine chocks is to ensure the proper alignment and stabilisation of ship engines, promoting overall operational reliability.

This is crucial as, left unaddressed, loose bolts can lead to heavy engine vibration, misalignment, bearing damage, and even crankcase explosion. Vibrations may also loosen torque on foundation bolts in crucial components like main engines, turbines, diesel-electric drives, gearboxes, and thrust blocks. Furthermore, if an engine is misaligned or chocks are incorrectly fitted, the overall life span is reduced, and replacement is costly from both an environmental and financial perspective.

Historically, metal has often been used for chocking, however, polymeric resin chocks prove to be a superior alternative. Compounds such as Belzona 7111 (Marine Grade), provide precise alignment with non-shrinking properties and, high impact and high compressive strength, saving time and manpower compared to conventional methods. Specifically designed to endure the physical and thermal shock common to marine environments. This makes it ideal for pouring foundations of heavy ship propulsion systems and other heavy equipment where alignment, and anchorage are essential.

Approved by the American Bureau of Shipping and Lloyd’s Register Classification, Belzona 7111 (Marine Grade) assures lasting alignment and durability, underscoring its excellence in ensuring safety and longevity in maritime applications. Minimising marine noise and extending asset life through solutions, such as those offered by Belzona, are effective and cost-efficient methods for reducing the negative impacts of shipping.

Belzona 7111 (Marine Grade) used to realign the main engine on a fishing boat with 500 tons of storage

Conclusion

A plethora of strategies will be necessary to achieve sustainable shipping. The quest for a sustainable fuel alternative, reducing underwater noise pollution, increasing efficiency, and the revolutionary use of coatings and composites are all integral strategies. Advanced polymeric solutions such as those produced by Belzona not only address critical issues such as cavitation and engine chocking but also offer a unique opportunity to revolutionise the industry. By simultaneously reducing capital expenditure, maintenance time and greenhouse gas emissions, these innovations play a pivotal role in steering the maritime sector towards a more sustainable and efficient future.

Using coatings and composites can revolutionise the maritime industry by simultaneously reducing capital expenditure and greenhouse gas emissions. Prioritising for the sake of the Blue Economy will propel the maritime industry into an era of environmental responsibility and economic resilience. Embracing these transformative solutions becomes not only a strategic imperative for the maritime industry but also a key enabler in realizing the holistic vision of a thriving Blue Economy that balances prosperity with responsible resource management.

Want to learn more about Belzona in the marine industry?

Click Here

An electronics manufacturer fully automated printed circuit board identification at the start of production on all SMT-lines with A8500 FlexCell Printer Applicators from Brady.

Challenge: Track from the start of production

A large electronics manufacturer wanted to bring printed circuit board traceability labelling to the start of its SMT production lines. This would enable the company to track every PCB in production by scanning labels at any location along the line.

Because of label variety and the number of labels required on each PCB, labels could not be printed in advance. Any equipment used to enable the solution had to be fast, and able to place labels on both sides of a PCB with 0,1 mm maximum tolerance.

Solution: Dedicated labels, automatically printed and applied

Brady proposed its A8500 FlexCell Printer Applicator and extremely thin B-7727 polyimide labels for auto-apply. The system recognises PCB’s and automatically prints and applies every label required on both sides of a PCB, in 3 seconds per label.

A8500 FlexCell Printer Applicator

The A8500 FlexCell Printer Applicator can print and place a label anywhere on a PCB in 3 seconds. Designed as a production line module with SMEMA-compliance, it can be plugged in anywhere along an SMT production line.

To further support the electronics manufacturer, Brady equipped the system with a software package that automatically recognises barcodes on PCB base plates. When passing through, the system auto-recognises the project the PCB belongs to. The FlexCell then prints and places all required labels in the right locations. Each label is placed with pressurised air, at 0,1 mm maximum accuracy tolerance, both on the top and bottom of PCB’s. Label data are sourced from the customer’s central ICT systems.

FlexCell liners were adapted to also enable automatic label placement at the edge of PCB’s, making full use of the system’s high label placement accuracy and precision.

In addition, a pause option was added for quality checks at discretion. The FlexCell simply resumes serialisation where it left off, without any further manual intervention.

Dedicated PCB traceability labels

After label sample testing, the electronics manufacturer selected Brady’s B-7727 polyimide label. Designed to withstand multiple cycles of harsh condition washes for printed circuit boards, the label stays attached and remains legible throughout printed circuit board production. 0.1 mm thick, it is able to resist temperatures up to 300°C for 80 seconds without any visible effect. This allows tiny label QR-codes to be read by scanners throughout production.

Results: Traceability at 3 seconds per label

With multiple A8500 FlexCell Printer Applicators in place, the large electronics manufacturer can quickly label printed circuit boards at the start of production. This enables real-time tracking of PCB’s in production and generates data for efficiency analysis. All without delays or production bottlenecks, and in full compliance with printed circuit board traceability requirements from customers.

Print and apply at production pace

Brady offers a range of systems that can print and apply labels automatically to support compliance and traceability for manufacturers worldwide. Our labels are researched, tested and adapted for automatic application to enable compliance and traceability at production pace. Learn more about automated Print & Apply Systems from Brady >>

Brady Corporation

+44 (0) 1295 228 288

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www.brady.co.uk

Axair are proud to have been awarded and delivered the entire polypropylene fans schedule for the prestigious National Oceanography Centre in Southampton (NCOS). 

This schedule of works is an exciting and significant project for Axair and showcases the quality and value of the polypropylene fume extraction fans that the company supply. The project which started over five years ago includes a specialist diagnostic hub for the study and diagnosis of disease and illnesses using the latest in medical technology to analyse anything from simple blood tests to more advanced genetic testing.

The retrofit, which had the objective of increasing energy efficiency with the introduction of EC components into the site, would be tackled in several phases due to budget restrictions and to ensure all components were integrated with the building management system seamlessly. Axair’s industrial and technical team worked collaboratively with the contractor, specifier and building management consultant to ensure accurate EC fume fan selections that would deliver the required operating duties required to provide supply and extract to multiple classified area categories across the building.

Our inhouse technical team worked to support all stakeholders with the integration of the EC fans and inverters into the building management system to deliver current monitoring solutions that could meet the objectives of the project:

To improve the energy efficiency and reduce fume extraction system energy consumption across the site.

During the lifetime of the project, the five-page fan schedules changed according to building updates, consultant amendments and legislation. Axair worked closely with the awarded contractor J&B Hopkins to deliver a suitable specification with required airflow and pressure duties of each plantroom application. Applications included ventilated specimen stores, down draught tables, ventilated cut up rooms, microbiological safety cabinets and autoclave in addition to multiple laboratories and processing rooms.  Duty and standby fans were chosen with inverters for additional control and to reduce overall fume extraction system energy consumption by slowing down fans when required allowing a more efficient start up on larger fans such as the S35.

The most impressive outcome of this project was that although Axair were awarded with the project, they were not originally named on the specification. Due to the tenacious, technical ability of our Industrial team, who are trained to fine tooth comb through specifications, they quickly identified any errors in the fan selections based on the given duties and made the necessary comments back to the consultants, showing a higher degree of precision, technical ability, and overall customer care to ensure the fume extraction systems would perform. Ultimately securing the order with the confidence of both the consultant and M&E contractors.

Energy efficient polypropylene fans featuring IE5, are designed to reduce fan energy consumption by up to 20% without affecting performance.  EC polypropylene fans come with inverters prewired with a 1m cable while the motor can be situated up to 25m away from the inverter. 1m cable was supplied as standard by Axair, therefore additional cable was provided by the contractor. The use of EC fans would assist with improving the BREEAM status with credit contributions in the Ene.07 category from increasing the operational efficiencies in the laboratories.

www.axair-fans.co.uk

At a major global blue-chip nickel Mine in Australia, authorised Belzona Distributor, Rezitech, provided a full turnkey solution to combat corrosion under insulation on an ammonium sulphate feed tank. Within the space of 24 hours, the 9.5 metre (31.2 ft) diameter tank (with a height of 2 metres (6.6 ft) from ground level) was repaired and protected against future corrosion with the industrial composite wrap system, Belzona SuperWrap II.

Figure 1. Composite wrap system curbs corrosion under insulation at nickel mine

Protective Coatings and Epoxy Repair Systems Support Transition to Net Zero

The Mine refines granulated nickel matte from their smelter into premium-grade nickel powder and briquettes containing 99.8% nickel. Nickel powder is further processed into nickel sulphate at a Refinery in Australia. Nickel sulphate is an essential ingredient in the lithium-ion batteries that drive electric vehicles (EVs). It could be argued that the increase in sales of EVs is one of the biggest climate wins of 2023. Indeed, according to the 2023 Report from Climate Action Tracker, of the 42 sectors which need

o achieve net zero status by 2050, the only sector which is on track is the share of EVs in lightduty vehicle sales. Considering how road transport currently accounts for 11% of global greenhouse gas emissions, EVs play a vital role in reducing these emissions.

As such, the polymeric technology required to repair and improve assets within the EV industry equally plays a vital role in supporting the transition to net zero. By repairing damaged assets instead of decommissioning and sending them to landfill, this significantly reduces the climate impact that would otherwise be incurred in this process.

Case Study: Feed Tank Suffering from Corrosion Under Insulation & SCC

The Customer’s stainless steel feed tank was suffering from corrosion under insulation and chloride induced stress corrosion cracking. They required a solution that would not only restore the integrity on the substrate, but also protect the asset against future corrosion damage. Not only this, but as the tank operates at elevated temperatures of approximately 70°C (158°F) and processes highly corrosive medium, the repair solution would need to be able to withstand these harsh conditions.

Figure 2. Tank Contents

Rezitech Specifies Belzona Composite Wrap Solution

Having worked with Rezitech over the course of five years, the Customer had complete confidence in the range of Belzona metal epoxy repair composites and industrial repair coatings the Distributorship offers. As such, they decided to contact them again for their advice and system recommendation

Following an inspection by Heath Westell, Sales Engineer at Rezitech, the composite wrap system, Belzona SuperWrap II, was specified.

Commenting on this specification, Heath said: “This composite wrap system is comprised of a fluid-grade resin system, a bespoke hybrid reinforcement sheet, based on fibre glass and carbon fibre, as well as a release film to compact and consolidate the application. The system is specially formulated to restore the strength of holed, weakened and corroded pipe and tank walls, making it the ideal solution for protecting the asset against corrosion under insulation for the long term. In addition, thanks to the cold-curing properties of the composite wrap system, this mitigates the need for hot work, making it a reliable alternative to welding.” 

Application Procedure:

Firstly, all traces of oil and grease contamination were removed using a suitable Rezitech Degreaser. Following this, the surfaces were grit-blasted to provide a surface cleanliness compliant with ISO 8501-1 SA 2½ (ASNZ 1627.4 class 2.5) with a minimum 75 µm (3 mil) rough angular profile.

Once the surface was prepared, the Belzona 9381 reinforcement sheet was measured out and then wetted out with the Belzona resin system. The resin was then systematically applied to the areas to be repaired. Following this, the Belzona reinforcement sheets were then applied to the tank in three layers. The compression film was then added to the top of the application area. Next, using a roller, the Belzona SuperWrap II composite wrap system was then spread, rolled and compressed to the surface of the tank. The system was then left to cure for approximately eight hours.

Figure 3. Stainless steel feed tank repaired and protected with Belzona SuperWrap II

Bypass the Need for Replacement with Polymeric Technology

By investing in the Belzona composite wrap solution, this enabled the Customer to successfully bypass the need to replace the corroded asset, and instead prolong the lifespan of the asset for years to come. Thus, this enabled the Customer to make significant savings in both time and money. In addition, given the important role EVs play in reducing global carbon emissions, it could be argued that polymeric technology also plays a fundamental role in supporting this transition by safeguarding the integrity of key assets within this industry.

Figure 4. Mitigate the need for replacement with polymeric technology

About Rezitech: Established in 1968, Rezitech is the sole Australian Distributor for Belzona. Rezitech offers a comprehensive range of industrial protective coatings and epoxy metal repair composites to many different industries including: oil and gas, mining, power and facilities maintenance, amongst others. For more information, please visit: www.rezitech.com.au/products/belzona

Figure 1. US’ first zero emissions, all-electric tugboat, the eWolf

In order to keep the planet on track for achieving net zero carbon emissions by 2050, at COP28, negotiators from 200 Parties agreed on the science from the Intergovernmental Panel on Climate Change (IPCC) that: ‘[…] limiting warming to around 1.5°C (2.7°F) requires global greenhouse gas emissions to peak before 2025 at the latest, and be reduced by 43% by 2030.’

Figure 2. Image: IREANA

Prior to COP28, in July 2023, the UN agency, the International Maritime Organisation (IMO), considerably vamped up its strategy on the reduction of greenhouse gas emissions from ocean freight. The Organisation’s revised targets aim to reduce carbon emissions from international shipping by 40% by 2030, and to achieve net zero by 2050, based on 2008 levels.

The Maritime Industry’s ‘Most Important Mitigation Measure’

One of the fundamental ways in which this sector can achieve this is through ‘scalable zero emission fuels’. According to a 2023 Report from one of the world-leading authorities on climate science, Climate Action Tracker: ‘To achieve full decarbonisation, the shipping sector will need to adopt alternative fuels, otherwise known as scalable zero emission fuels, to power vessels.’ The Report goes on to describe how: ‘This is the most important mitigation measure.’ Scalable zero emission fuels typically refer to hydrogen, ammonia, e-methanol and electric battery.

Considering the seismic reduction in global greenhouse gas emissions required by the maritime industry by 2030, advances in technology, such as the US’ first zero emissions, all-electric tugboat, the eWolf, is a huge step forwards in terms of decarbonising this sector.

The US’ First Zero Emissions, All-Electric Tugboat

Launched in 2023, the 25 metre (82 ft) eWolf is leading the way in terms of mitigating the

climate impact of the maritime sector. Over the first 10 years of its use, the operation of the new ‘eTug' will reduce 178 tons of nitrogen oxide (NOx), 2.5 tons of diesel particulate matter, and 3,100 metric tons of carbon dioxide (CO2), versus a conventional tugboat.

The eWolf is capable of speeds of up to 12 knots, and will be powered by a 6.2 megawatt-hour main propulsion battery and two electric motors. The electricity comes from a charging station that is part of a microgrid facility, equipped with two energy storage containers. Battery modules in each container have a storage capacity of nearly 1.5 megawatt-hours.

Bonding Solution Required for Front Fender

The front fender for the eWolf needed to be bonded together using a strong adhesive that would withstand pushing and pulling forces during the process of adhering the fender to the eTug. Having established confidence in Belzona technology from using their polymeric systems in previous applications, the Customer chose Belzona once again for the application.

System Specification: Elastomeric Primer and Polyurethane Resin

Following an inspection by Micah Heath, Technical Consultant at Belzona Distributorship, Belzona Alabama Belzona Alabama, the fast curing, one-part elastomeric primer, Belzona 2911 (Elastomer QD Conditioner), was specified. This conditioner is optimised for adhesion to a variety of substrates including rubber, as required for this particular application. For the bonding, the polyurethane resin, Belzona 2211, was specified. This flexible rubber repair material is optimised for applications where high build, durability and elasticity are required.

Application Procedure

Commenting on the application procedure, Micah said: “Once the required surface preparation was completed using grinding wheels and MBX Bristle Blaster, the conditioner, Belzona 2911 (Elastomer QD Conditioner), was applied. As soon as the conditioner was touch dry, Belzona 2211 was used to attach the plugs into the fender, and then attach the 3-part fender together. The application team used a manual cable puller to apply the necessary pressure to ensure the various surfaces were sufficiently pressed together. Once completed, the application was left for 36 hours to cure, achieving an excellent mechanical bond.”

 Figure 3. Fender plugs prior to attachment

Figure 4. Polyurethane resin, Belzona 2211, applied to prepared surface

Figure 5. Come-alongs used to hold the sections together during curing process

Policy is Key Driver in Roll-Out of Zero Emissions Technology

Over the past few years, numerous policies have been launched worldwide which have provided huge cash injections for technologies and industries that support the net zero by 2050 pathway. One of the world-leading policies is the US’ Inflation Reduction Act (IRA) Inflation Reduction Act (IRA) which includes $369 billion (US dollars) of investment.

According to the Climate Action Tracker, ‘[…] thanks to the passage of the IRA in the United States, companies are announcing hundreds of clean energy manufacturing facilities, turbocharging battery and electric vehicle production and creating tens of thousands of new jobs.’ A continued investment will continue to ‘[turbocharge]’ advancements in technologies such as the eWolf. In turn, technology like this will help the sector to achieve its decarbonisation targets.

Decarbonising the Marine Sector with Polymeric Technology

In addition to pioneering technology like the eTug, polymeric systems also play a key role in the decarbonisation of this sector. Belzona’s circular economic business model is grounded in the practice of repairing and improving damaged assets, rather than decommissioning and replacing them. Not only does this allow the asset owner to make considerable financial savings, but it also mitigates the carbon footprint incurred during the process of replacing damaged assets. In turn, this supports a net zero by 2050 pathway, in line with the Paris Agreement. Maritime Approvals In addition, Belzona systems are manufactured according to the ISO 9001 quality management systems and are approved by classification societies from all around the world including: Lloyd's Register, American Bureau of Shipping, Bureau Veritas, RINA Services, DNV, China Classification Society and the Korean Register of Shipping.

For more information, please visit: www.Belzona.com