Latest Case Studies & White Papers

How Data-Driven Design and Predictive Care Are Revolutionizing Bulk Handling Systems

Author: Laura Villa, CEO

Every plant manager knows the sinking feeling: a critical piece of equipment fails during peak production. Downtime cascades through the operation. Crews scramble. Revenue evaporates by the hour. But what if you could see the failure coming weeks—or even months—before it happened?

This isn't science fiction. It's the new reality of predictive engineering, where advanced simulation meets real-time monitoring to transform bulk handling reliability from an art into a science.

Read the full article by clicking the link below.

ideco.docx

Effective monitoring of critical infrastructure is an essential requirement across the power generation, Oil, Gas and Petrochem industries where smooth running and trouble-free system operation is vital, especially in today’s highly competitive and energy cost-conscious environment. Condition monitoring specialist SENSONICS are experts in developing highly effective monitoring systems based on over 50 years of experience, including vibration monitoring products. A good example of this is the recent completion of a cooling tower monitoring project at a major Petrochemicals plant.

The Project Engineer at the site confirmed they were looking for a suitable system to monitor and protect cooling tower fans to prevent issues in case of failure of the fan blades. The requirement would be for individual systems to monitor each of the twenty motor / gearbox driven fans which were located between the motors and fans around the base of the cooling tower.

Confirming the specific requirements of the application, the Project Engineer commented, “The fan speed is 131RPM / 2.18Hz and what we want is to have a single transducer mounted on the gearbox (each fan is mounted on the gearbox output shaft) and the issue we want to address is the potential failure of the fan blades. When this has happened, the vibration has been so severe it damaged the concrete platform that the fan assembly is mounted on, as well as damaging adjacent fans from the fan projectiles”. Also, it was confirmed that, “The atmosphere where the fan is mounted is very wet and windy as the fans pull moist air out of the cooling tower packing and blows it across the gearbox and motor.”

Confirmation of these specific issues and challenges initially suggested the need to install a suitably ranged 4-20mA vibration transducer and then feed this to a closely located unit that has the start / stop buttons for the fans, enabling the tripping of a fan if the vibration is too high.

There was also a need to feed the overall vibration levels to the main plant DCS system. Due to the specific requirements of this application the frequency of response of the transducers would need to be lower than below 2Hz and there was no requirement for any local display or further diagnostics. A simple system which would reliably trip the fan out if it were failing and additionally to give an indication on DCS for the overall vibration level.

Conclusion

Once the specific requirements of this vibration monitoring application were confirmed, Sensonics were able to suggest and supply a combination of their DN26 G3 dual channel protection system along with their VEL/GLF low frequency (slow speed) velocity transducers. Established in the condition monitoring market for many years Sensonics has supplied thousands of these compact and innovative, din rail mountable DN26 G3 dual channel vibration monitors which have delivered reliable and cost-effective vibration monitoring across a wide range of installations. This high performance fully programmable signal conditioning unit is capable of monitoring 2 channels of absolute vibration, shaft vibration or shaft position, while a third channel option is available for measuring speed or for use a phase reference.

To complete the solution for this application is Sensonics VEL/GLF, a low frequency velocity transducer (slow speed) option proved to be ideally suited to the large fans which were operating at a minimum RPM. This electro dynamic sensor provides a superior performance compared to piezo-electric devices by combining high measurement sensitivity with a frequency response down to 0.5 Hz.

This level of sensitivity, along with excellent noise performance, provides the necessary dynamic range required for detailed analysis of gearbox vibration, so is ideal for measuring velocity vibration on equipment with speeds down to 30 RPM. Furthermore, the VEL/GLF has advantages over traditional piezoelectric based velocity vibration sensors which are susceptible to many forms of interference in low frequency applications that can result in spurious readings and alarms.

As a result of its robust design, the VEL/GLF offers high noise immunity due to the low impedance electro dynamic nature of the sensor assembly.

In addition to the filtering of high frequency events and since no electronic integration is required, means the design of the sensor is immune to the saturation problems that impair the reliability of other piezoelectric devices.  

More at: https://www.sensonics.co.uk/vibration-position-monitoringhttps://www.sensonics.co.uk/vibration-position-monitoring  

Let’s get straight to the point: industrial maintenance isn’t a solo act. It’s not a single department heroically keeping the lights on and the machines running. It’s a team sport. And if you ask me, it’s not just like football, it is football.

Before you dismiss this as a gimmicky metaphor, hear me out. I’ve been obsessed with football since I was a kid. If I wasn't playing the game, I would be watching the game. I'm a big fan of the Dutch national team but blame my parents for being born two weeks too late. Two weeks before I was born, 'Oranje' won their biggest and only international title at the '88 European Championships. Being a fan hasn't always been easy, but I have kept myself busy.

I’ve also spent the last eight years deep in the world of enterprise asset management (EAM), working with industrial teams across Europe. And over time, I’ve noticed an uncanny parallel between the game I love and the profession I’ve grown to respect.

Teamwork Wins Titles, and Maintenance Goals

In football, no single player wins a match. Even the brightest striker needs the right ball at the right time. Likewise, maintenance doesn’t happen in a vacuum. It relies on operations to flag the early signs of failure. It depends on safety to ensure tasks are performed within compliance frameworks. And it only succeeds when all three - operations, maintenance, and safety - work in synchronization.

At Ultimo, we call this the Circle of Collaboration. Imagine a Rondo drill: players forming a circle, passing with precision, reading each other’s moves, and improving with each touch. Replace the ball with data, and that’s what good asset management looks like. Maintenance, operations, and safety all pass insights, decisions, and feedback in a closed loop. When the system works, it’s seamless. But like football, when one player’s out of sync, the whole formation falls apart.

Strategy, Not Firefighting

In football, winning isn’t just about running hard, it’s about playing smart. You analyze the opposition, you adapt your formation, you anticipate rather than react. The same mindset needs to apply on the plant floor.

Too often, maintenance teams operate in firefighting mode. Assets fail, engineers scramble, and every pound gets spent putting out fires. But with the right data - reliable, high-quality, and timely - you shift from reactive to proactive. You stop guessing and start coaching.

Just like a good football manager uses performance data to adjust tactics, reduce injuries, and maximize output, maintenance leaders must rely on actionable insights. Why did a failure occur? How long did it take to resolve? What could prevent it from happening again?

Data turns chaos into clarity. It turns downtime into learning. And most importantly, it empowers every department to pull in the same direction.

Who’s Who on the Field?

Let’s take the analogy even further. Picture your maintenance team as strikers. They’re the stars who ultimately score by keeping equipment running and reducing downtime. Operations? They are your first line of defence against disruption. They monitor assets daily, report anomalies, and provide the foundation. And safety? That’s your midfield - linking the two, controlling the tempo, recovering from mistakes, and ensuring everyone plays within the rules.  They assure you are in control, on the shop floor and on the pitch.

When these roles click, you achieve Total Asset Management, much like the Dutch pioneered Total Football - a system where every player adapts, covers, and contributes dynamically. It's not rigid. It's intelligent. And it's built on trust, communication, and shared objectives.

The Role of Technology: Your Coaching Staff

Even the best teams don’t rely solely on their players. Behind every successful club is a sophisticated support structure - analysts, coaches, nutritionists, psychologists. In asset management, this role is played by your systems and platforms.

An EAM solution like Ultimo isn’t just a digital tool. It’s your tactical playbook, your assistant coach, and your data analyst rolled into one. It integrates with your enterprise resource planning (ERP), connects to Internet of Things (IoT) devices, and supports core processes like work order management, safety procedures, and inspection planning. It centralizes your operations into a single source of truth.

Good EAM systems are designed to promote collaboration. Work permits, lockout/tagout procedures, risk assessments - they’re all baked into the same environment. That’s how you align departments without adding complexity.

The Spearman Principle: From Physics to Football to the Factory Floor

Still think data’s just a buzzword? Consider Liverpool FC’s William Spearman, a physicist who helped discover the Higgs boson at CERN before joining the club as a data analyst. He now applies scientific rigour to understand passing networks, space control, and player positioning.

What if we applied the same approach to maintenance?

What if every equipment failure was analysed like a missed scoring chance? Every maintenance route trained  like a set piece? Every inspection treated like match preparation?

This is not fantasy. It’s the logical evolution of our field. The best-run plants of the future will study their operations with the same level of detail and ambition that elite football teams study the pitch.

Final Whistle: It’s All About Trust

You can’t automate what you don’t understand. You can’t optimize what you don’t measure. And you can’t lead without trust. Trust in your data, your systems, and your team.

Whether you’re on the shop floor or the football pitch, the formula is the same:

• Play as a team
• Use your data wisely
• Build trust that lasts.

If there’s one lesson football has taught me, and asset management has reinforced, it’s this: Data changes the game. But teamwork wins it.

Article written By Berend Booms, Head of EAM Insights at Ultimo

Reinforcing the piers that support a major UK rail viaduct spanning a river estuary is no easy task, which is exactly why the specialist marine subcontractor appointed to undertake this project approached Hoist & Winch Ltd for the optimal lifting solution.

The brief provided to Hoist & Winch was for the supply of a turnkey lifting solution comprising two sets of four hoist units suitable for a marine environment. These hoists were to be suspended from temporary scaffold structures fixed to two separate motorised floating pontoons. As part of an innovative approach to a complex challenge, the hoist-mounted pontoons would serve to locate special horseshoe-shaped reinforcing concrete collars either side of one of the bridge piers at high tide, prior to joining the collar halves together above the water with connection pins. Finally, the collar halves would require lowering to the river estuary bed for permanent fixing to the piers with concrete at low tide, thus providing the necessary reinforcement.

To establish the optimal package of hire equipment, as well as site installation, load testing and additional technical support services, Hoist & Winch consulted extensively with both the motorised pontoon designers and installation personnel responsible for lowering the special concrete collars into position.

After reviewing all the information from project stakeholders, Hoist & Winch subsequently proposed eight JDN top-hook suspension air-powered hoist. Each of these 3t swl (safe working load) hoists featured its own heavy-duty steel lubricator coupled with appropriately sized air supply hoses. The two sets of four hoists units would be operated from their own individually connected, heavy-duty (brass) two-button pendant control.

In order to monitor the load applied to each hoist unit and assist with delivering a balanced collar lowering procedure, Hoist & Winch also provided eight telemetry load cells of bow-shackle design. These load cells served to connect each hoist unit to its local scaffold anchor support position, transmitting individual hoist load data via radio signal to a central laptop display. Armed with this data, the appointed person directing lifting operations could instruct each hoist operator accordingly to ensure the load was evenly distributed between each set of four hoists and that each collar was lowered into position while remaining level.

Prior to commencing the process of installing and lowering the concrete collars, Hoist & Winch carried out the installation of the eight air-powered hoist units. This work included pre-use inspection, static load/deflection testing, and LOLER (Lifting Operations and Lifting Equipment Regulations) certification of the temporary scaffold structure and complete hoisting system.

Hoist & Winch also provided technical consultancy as part of the overall package, delivering guidance on important project areas such as lifting equipment legislation, lifting operation planning and management, and specification and procurement of the portable diesel-powered air compressors to power the hoist units. In addition, the company delivered full handover training for operators.

Both the specialist marine subcontractor and end client were extremely pleased with the final outcome, which saw the successful installation of two sets of trial pier-reinforcing concrete collars to the viaduct as part of a safe and controlled process.

“This specialist project demanded the application of our expertise and experience to ensure a successful conclusion in line with the appropriate safety standards and high performance levels demanded by our client,” says Andy Allen, Director of Hoist & Winch Ltd. “We worked closely with project stakeholders to ensure the delivery of a robustly engineered lifting solution with precision control. Quality solutions and service from Hoist & Winch once again led to a project that concluded with the highest levels of customer satisfaction.”

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web: www.hoistandwinch.co.uk

When a landmark building in Nottingham required the replacement of its fabric tensile roof covering, the subcontractor tasked with this critical work turned to the expertise of Hoist & Winch Ltd for the roof lowering and lifting solution. The eye-catching building, a former HMRC complex similar in design to London’s O2 Arena, is today part of Nottingham University’s Castle Meadow Campus.

The leaking tensile roof covering had reached the end of its 30-year lifespan and required replacement. To ensure the optimal solution to this technically complex challenge, the specialist subcontract responsible for the job approached Hoist & Winch. The objective for Hoist & Winch was to specify and supply a complete hoisting solution that would enable safe, even lowering of the original fabric roof to ground level and raising of the replacement fabric roof to its final installation height.

Following a number of site meetings and consultations with both designers and roof installation personnel, Hoist & Winch was able to propose a complete package of equipment and technical support.

At the centre of the proposal were 12 Yale/CM Lodestar electric chain hoists. These 2t swl (safe working load), 110V top-hook suspension hoists were coupled with correctly sized 30m long power feed/control cables. The idea was to operate the hoists simultaneously in sets of four while suspended from the customer’s specially designed lifting beams. Hoist & Winch also provided three separate single free-standing control stations of bespoke design to manage hoist unit motion, either individually or in sets of four, during lowering of the original fabric roof and lifting of its replacement.

                                                                                                                                                            Continued ……

Another aspect of the project saw Hoist & Winch supply a combination of 15t and 6.3t swl William Hackett lever hoists to assist with de-tensioning the original fabric roof prior to lowering operations and re-tensioning the new fabric once lifted into its final position.

As always, technical consultancy proved a core element of the overall package from Hoist & Winch. The company’s highly professional approach ensured the specialist roofing subcontractor received guidance on project-critical factors such as lifting equipment legislation, lifting operation planning and management, overall design and sizing of two bespoke portable electrical transformers, electronic load cell selection, selecting loose lifting tackle, and site examination and testing procedures prior to the commencement of lifting operations.

“The outcome was the safe and successful removal of the original fabric roof and the installation of its replacement as part of a finely controlled, smooth process,” reports Hoist & Winch Director Andy Allen. “The customer was delighted with the professionalism of our expert team and the solutions we proposed. Taking projects like this from concept to fruition is where we excel, ensuring our customers meet all of their objectives in a safe, competent and timely manner.”

Such was the impression made on the specialist roofing subcontractor that it subsequently engaged Hoist & Winch in further work to adapt the already acquired lifting system and used the knowledge gained from the Nottingham project to bid successfully for another multi-point lifting project in Copenhagen.

Visit www.hoistandwinch.co.uk for further information and to view recent case studies.

To ensure the safe, effective and efficient transfer of plant equipment into the basement energy room of a new residential tower block in London, a major construction project leveraged the advantages of appointing Hoist & Winch Ltd as its supplier of turnkey lifting equipment. Tasked with meeting the requirements of a technically challenging brief, Hoist & Winch demonstrated why it has become the nation’s go-to solution provider of high-quality lifting systems.

Many new tower block development projects face a common challenge: how to install large, heavy pieces of equipment into the building’s energy centre, typically located in the basement. Specifying the optimal hoists is paramount to project success. Fortunately, the subcontractor supplying and installing the energy room’s plant for this particular project knew where to turn for a turnkey lifting solution: Hoist & Winch Ltd.

Hoist & Winch has extensive experience in all kinds of construction and industrial lifting applications. The company offers sales, installation, service, inspection, repair and hire services, with a special emphasis on project work. Supplying the optimal solution, with safety as the number one priority, is always the objective.

During the design phase, after formal tender and contract award, Hoist & Winch set about identifying the optimal solution by carefully assessing the specific lifting requirements. The project required the installation of hoists on both the upper and lower ground floor levels to ensure the successful lifting and transfer of large energy plant. It was clear from the outset that the solution would need to overcome the issue of very tight headroom clearances due to the size of the equipment.

After thoroughly considering all aspects of the project, Hoist & Winch Ltd was able to put forward its proposal, recommending two William Hacket low-headroom manual hoists, both with a hand-geared trolley. Offering a safe working load (SWL) of 2.5t each, the hoists provide 8m of lifting height and run on beam lengths of 8.5m and 7.0m.

Hoist & Winch duly submitted its design proposal, including drawings and structural calculations, for approval by engineers at the main contractor. Following approval, the company commenced manufacture before delivery to site.

During the installation phase, Hoist & Winch tested the installation anchor points to 1t before raising each beam into position using hand chain blocks. Elevating the beams to full height and clamping them hard against the concrete ceiling ready for drilling required the use of special lifting rigs. Once in position, the company proceeded with drilling operations and resin anchor installation for all ceiling anchor points after meticulously cleaning each hole with a special heavy-duty internal brush and suction pump. Following the specified resin curing time, Hoist & Winch tightened each anchor bolt to the required torque levels.

LOLER (Lifting Operations and Lifting Equipment Regulations) inspection of the lifting beams and manual chain hoist units was the final operation. This activity included dynamic load testing of both beam lengths with a 2.5t skid-mounted test load followed by 125% static proof load test in accordance with BS 2853 2011. As a point of note, following customer handover, the hoists were to remain in place for use by the on-site maintenance team.

“We provided the client with a comprehensive project records and documentation package upon completion of works, which is standard practice,” says Hoist & Winch Director Andy Allen. “We then went through the handover process to ensure total peace of mind for our client. At Hoist & Winch, our focus is on ensuring customers benefit from our exceptionally knowledgeable team who never fail to deliver on their promise of providing a detailed and proficient approach to every project.”


Visit www.hoistandwinch.co.uk for further information and to view recent case studies.

by Steven Sandler, founder and CEO of Picotest

Modern electronic systems require precise and reliable power delivery, yet designing effective Power Distribution Networks (PDNs) presents significant challenges. Issues such as noise, instability, and inappropriate capacitor selection can compromise performance and lead to device failures. How can engineers address these challenges? The key lies in leveraging advanced analysis tools like Vector Network Analyzers (VNAs) from the early stages of design and throughout the development process. These tools are essential for identifying potential issues and preventing instability or other faults in the power distribution system. Whether resolving existing problems or designing advanced systems, using a state-of-the-art analyzer provides the precision and insights needed to optimize designs and ensure robust performance.

PDNs are a critical but often overlooked component of modern electronics. These networks, comprising printed circuit board (PCB) power planes, bulk capacitors, and decoupling capacitors, deliver electrical power from Voltage Regulator Modules (VRMs) to Application-Specific Integrated Circuits (ASICs) and other components that require precise power. Proper PDN design is essential for maintaining device stability and performance, ensuring power delivery is both reliable and free from noise or instability.

A common misconception in PDN design is the oversimplified belief that "lower impedance is always better." While low impedance is generally beneficial, achieving a "flat impedance" profile across the operating frequency range is far more critical. Another frequent error involves assuming that a diverse selection of capacitors automatically leads to optimal performance. Effective PDN design requires meticulous analysis and strategic component placement to meet specific impedance and stability criteria, rather than relying on arbitrary component choices.

Challenges in PDN Design

PDN design for modern devices, particularly those with compact, high-speed circuits, poses numerous challenges. A primary concern is minimizing the distance between VRMs and ASICs to reduce noise and improve power delivery efficiency. Capacitor selection and placement are vital for achieving a flat impedance profile, which mitigates noise and enhances stability. However, insufficient validation during the design phase often results in performance issues, such as excessive noise or instability, especially in circuits with narrow voltage margins.

The interrelation of noise, impedance, and stability further complicates PDN design. Noise is generated by dynamic current changes within the ASIC, and the PDN must counteract these variations effectively. Poorly designed capacitors can destabilize the control loop, leading to uneven impedance and increased noise. Given the tight operating margins of modern ASICs, effective noise mitigation is critical to ensuring device functionality.

Avoiding Common Pitfalls

One of the most frequent mistakes in PDN design is relying on inaccurate capacitor models for simulations. Many engineers also mistakenly assume that the same models can be used interchangeably in SPICE and electromagnetic (EM) simulators, leading to flawed designs. Tools like the Bode 500 Vector Network Analyzer address this issue by providing de-embedded capacitor models tailored for both SPICE and EM simulation environments. Picotest offers both component mounts and component test fixtures that allow accurate micro-Ohm measurements with the Bode 100 and Bode 500 Vektor Network Analyzers, as well as other instruments up to 2GHz and higher.

Another common error is underestimating the importance of thorough validation. Advanced tools, such as the Bode 500 Vector Network Analyzer and Picotest probes, simplify the validation process, allowing engineers to detect and resolve issues early in the design phase. By emphasizing accurate modeling and validation, these tools significantly reduce the risk of noise and instability in PDNs.

The Right Tools for the Job

Advanced tools like OMICRON Lab's Bode 500 Vector Network Analyzer are indispensable for tackling PDN design challenges. This device enables precise impedance measurements across a wide frequency range using the 2-port shunt-through method, a widely recognized standard in PDN analysis. It supports capacitor characterization and the creation of simulation models, facilitating the selection and placement of components. This capability is particularly valuable since vendor-provided capacitor models often lack the precision required for PDN design. The Bode 500 Vector Network Analyzer compensates for this shortfall by generating more accurate models.

The instrument also offers features such as Non-Invasive Stability Measurement (NISM), support for Touchstone file formats, and compatibility with various measurement configurations. These capabilities ensure PDN stability and help minimize noise. By incorporating PDN probes, such as the P2102A and P2105A models, PDN analysis can be further enhanced. Designed for examining PDNs, these probes enable accurate measurements of individual power rails within complex systems. Their advanced shielding and interchangeable heads support diverse use cases, including near-field analysis and step load testing, while minimizing interference.

Conclusion

Excelling in PDN design requires a methodical approach, employing advanced tools for precise measurement and analysis. By focusing on accurate capacitor modeling, achieving flat impedance profiles, and rigorous validation, engineers can overcome the challenges of modern PDN design and ensure the stability and performance of electronic systems. For those new to the field, committing to continuous learning and engaging with expert resources will pave the way for success.

These networks, comprising printed circuit board (PCB) power planes, bulk capacitors, and decoupling capacitors, deliver electrical power from Voltage Regulator Modules (VRMs) to Application-Specific Integrated Circuits (ASICs) and other components that require precise power.

Modern electronic systems require precise and reliable power delivery, yet designing effective Power Distribution Networks (PDNs) presents significant challenges.

A primary concern is minimizing the distance between VRMs and ASICs to reduce noise and improve power delivery efficiency.

Advanced tools like OMICRON Lab's Bode 500 Vector Network Analyzer and Picotest’s PDN probes are indispensable for tackling PDN design challenges.

Smart Measurement Solutions | OMICRON Lab

www.picotest.com

Deep cleaning in continuous operation: new Sword Brush® with microfilament technology thoroughly removes even fine dust particles

Compact design allows easy integration into various processing lines

Dust particles are a constant challenge in furniture production, as they can damage surfaces and, if not removed efficiently before each individual processing step, result in rejects. Chips and particles are basically removed by hand or by using compressed air. However, these cleaning methods are not sufficient as particles are merely carried away and do not provide a consistently high cleaning quality. Wandres has therefore developed the new Combi Sword Brush Una U, which exploits efficient microfilament technology. The microfilaments create a particularly large contact area with the dust particles. The particles adhere to the filaments and are reliably removed from the surface without the need for cleaning agents. Cleaning with the Combi Sword Brush Una U eliminates the need for cleaning and anti-static agents, which reduces both operating costs and environmental impact. The filaments can also penetrate fine surface structures due to the very thin filament diameter, achieving a deep-cleaning effect. The integrated pressure buffer, which allows individual filaments to adapt to the surface shape, provides for a consistent cleaning quality. The Sword Brush® was specially developed to be integrated into existing production lines, and its compact design makes it easy to retrofit.

“Mass production of furniture boards and panels generates a considerable amount of dust and particles through drilling, sawing and milling. These may damage the surfaces during stacking and transport or impair subsequent production steps. The result can be production downtime and loss of quality

if particles are pressed into the surface, for example,” says Martin Tritschler, Head of Sales at Wandres GmbH micro-cleaning. Industrial environments where high production speeds and flawless results are required, need efficient cleaning solutions to thoroughly remove various types of particles and chips. A range of methods are available, such as compressed air cleaning or manual dust removal. However, manual procedures are time-consuming and generate high labour costs. Compressed air processes are expensive to operate and are unable to remove very fine dust that adheres strongly to the surface. “Manual cleaning effectiveness varies depending on the daily performance of the particular employee in question, while compressed air cleaning can result in particles being carried over into the production environment,” Tritschler adds.

On the other hand, it takes just a few steps to integrate the various types of Combi Sword Brushes into industrial processing lines. They are specially designed to react appropriately to the changing particle load in continuous operation and ensureonsistently high cleaning effectiveness. 

Large contact area and constant cleaning result 24/7

At the heart of the new Una U product range are special microfilaments. Due to their fine structure compared to conventional brushes from other manufacturers, they can reliably pick up even tiny dust particles and feed them into the extraction system. The pressure buffer is a crucial element here, as it ensures that the filaments stand vertically on the surface without bending, meaning they are in the best position to remove the particles from the surface. This mechanism enables the system to adapt to different surfaces: “Because the brush is pressed onto the panel with a constant pressure, a consistent cleaning performance is ensured over the entire contact surface,” explains Tritschler.

The brush regenerates itself automatically thanks to a continuous self-cleaning function, which enables consistent results around the clock. Particles are removed from the brush mechanically via a roto rack and pneumatically via a self-cleaning nozzle. Afterwards, they are driven towards the suction unit. With particularly high particle volumes, the cleaning result can also be improved by combining air and wiping technology. By installing an air pre-cleaning stage at the infeed of the brush, large quantities of particles are sucked up directly instead of falling to the floor. This always keeps the working environment clean.

Compact design for easy integration

However, Wandres has not only been focussing on cleaning efficiency during the development of its products. “Low resource consumption and short maintenance and assembly times are key factors in an industrial environment,” explains Tritschler. This is the reason why the Combi Sword Brush Una U does not need any additional cleaning agents. However, it may still make sense to equip the brushes with the Ingromat system for some surfaces or applications, for example before applying the topcoat. In this case, instead of microfilaments, brush filaments with a slightly larger filament diameter are used. These are permanently coated with a microfilm of the cleaning and antistatic agent Ingromat. Micro-moistening ensures the necessary adhesion between the dust particles and the filaments and minimises the use of cleaning agents, while the subject surface remains dry. The brush system does not take up much space in existing production lines because of its small footprint. The machine is also available in different nominal widths so that it can be adapted to the roller conveyor width on site. “Production of furniture panels always creates chips and dust. We therefore felt it was important to provide customers with a solution for many cleaning applications that can be easily and reliably integrated into production processes without impairing them or slowing down the process flow. At the same time, a reliable cleaning result is guaranteed in continuous operation – irrespective of the design and surface quality of the panels or the production speed of the systems,” summarises Tritschler.

Further information is available online at www.wandres.com

At its dairy operation in the Yorkshire Dales, the introduction of new separators has given Metcalfe Farms the opportunity to futureproof the pumps it uses to transfer large volumes of slurry from its 2,000 (1,300 dairy) cows.

Separating slurry has undoubted benefits, but putting together a streamlined slurry transfer system covering three tanks, has presented plenty of challenges, especially with the need to feed the site’s 200kWh biogas plant.

Aside from the separators, one of first issues was to address the final pump in sequence that ultimately sends slurry (about 6% to 8% dry matter) about 120 meters (and 10 meters of lift) up to the 3,500m3 anaerobic digester.

Annoying bits and pieces inevitably find their way into slurry, which was enough to make the pump block quite regularly.

“I used to dread coming down here to sort it out,” said Robert Metcalfe, who oversees all things engineering on the dairy side of the business.

“The pump did an okay job when working but wasn’t the best with solids. It wasn’t a pleasant job spending over an hour unblocking it each time; a two-man job, so all very time-consuming, especially having to retrieve it with a pipe because there was no clutch at the bottom.”

That’s all changed now with the old unit replaced by a Chopper Pump made by Landia, who also supplied an integrated guide rail and a bespoke pipework system for easy access and lifting.

‘It is much a better design’

“Everything flows through so much smoother now,” added Robert. “It is much a better design. You don’t have to worry about any sort of pipe bending or extra weight of the added pipe. Generally speaking, the new pump doesn’t block, although just recently a large chunk of rope stopped it! But unlike before, it’s now a job for one person, and on this occasion, only took 20 minutes before simply lowering it back in again.”

‘Digestate from the AD plant

provides significant benefits’

At the biogas plant, which is run by Iona Management Services, a second CHP (combined heat and power) engine has

recently been added, which will help increase the amount of clean energy that is exported to the grid. Metcalfe supplies a slurry-only feedstock to the AD plant, and then buys power back at a discounted rate for its own use. In the winter this is around 300 kilowatt hours, rising to 360 kilowatt hours in the summer. In addition to providing power for the dairy and the sell-on to the grid, the digestate from the AD plant also provides significant benefits, as Robert Metcalfe explains:

“The digestate does wonders for our grassland. We spread a little bit on the crops, but it’s mainly focused on the grass. This year we did five cuts over 1,000 acres. We hardly spend anything on chemical fertilizer now.”

Working closely with Landia to look at how best to integrate the new separators, a 22kW pump was chosen to manage the slurry feeding task, with an existing long-shaft Landia pump moved up from its existing task on another tank.

“We’ve had this pump since 2004,” added Robert Metcalfe, “which has understandably endured plenty of wear, but when tested by Landia engineers during a service, the 20-year-old unit was still happily pumping full pipe, which I have to admit, I was pleasantly surprised by. Now that we have separators, we can remove solid material to reduce our environmental impact.”

To replace the old long shaft unit, a new 7.5kW Landia Chopper Pump has now been installed so that slurry levels don’t rise. Meanwhile, the existing Landia long shaft chopper pumps, which have already been in service for 20 years, since Metcalfe had its first shed, continue to work away.

Very strongly built’

Robert Metcalfe continued: “The pump at the front of the loop system that has been created gets plenty of pain, so no surprise it’s had some repairs over the years, but steadily pumping away, it, with the others, has ensured that the dairy’s channels never fill up. We’ve found that by keeping our channels narrow, the pumps keep them flushed out completely, whereas with wider channels, the whole thing would still need flushing out. Now that we have it all set up on timers, it’s seamless, so far less hassle.

“The Landia pumps are very strongly built things, and I like the fact that they are electric and quite modular, so we don’t have to hook up to a tractor. This very much fits in with what we constantly work towards with fewer engines turning and less burning of diesel. One Landia pump we’ve had now for three years, and it’s never given us a bit of trouble.”

Over in the Metcalfe milking parlour, Robert has been glad to see the back of having to replace small vortex pumps that

blocked or blew completely, even though the liquids are very watery.

He explained: “As soon as any foreign debris or plastics came into play, straining the pump, we were having to buy a new one almost every six months due to burnout or component failure, so as they clearly weren’t up to the job, I called Landia for help. Also, the pump(s) had been installed on winches and over time, blockages and sediment buildup forced us to keep raising the pumps closer to the top of the tank, which in turn meant we ended up with sediment right up to the mouth of the tank.

‘Since we’ve had it installed, we haven’t had to touch it’

“We now have a new 5.5kW Landia pump that just flies through any debris or solids, which are an inevitable part of dairy wastewater/slurry. Nothing settles out with this new, much faster pump. It’s absolutely spot-on, and what’s great is that it is completely automatic. Since we’ve had it installed, we haven’t had to touch it. You can configure it so that in this case it knows we want to keep this tank pumped out and empty. The sensor knows the tank’s dimensions and capacity. It is so much better than what we're doing before.”

Synching the pump operation, together with the investment in separators is just part of how Robert Metcalfe is helping focus

on improvements to help take the diary part of the business forward, but without expanding too quickly. The dairy provides around 45 tonnes of milk per day to Paynes Dairies at Boroughbridge. Exceptionally high animal welfare standards for the Metcalfe cows continue to see a rise in yields.

“Going forward,” said Robert, “everything matters, even the little things. For all its benefits, we’d possibly consider sand bedding, but I don’t think our slurry channels would take it, and there’ such a big wear factor on pumps and machines. The sawdust we use is perfect, apart from the price!

“We’ve also been improving the lighting for our cows, again with some help from an automatic, dimmable system. Previously in hot summer spells, you could see that our cows were uncomfortable, which we don’t want. The milk output would drop. As well as the lighting, we’ve also put up new roof sheets to block out any intensive heat, which has made a big, positive difference.”

He concluded: “In time here we will probably phase out other brands of pumps as they come to the end of their life or cause problems, and just stick with Landia. I think it helps that they focus on pumps, rather than some who try to provide everything, plus we always get very good backup and no problems with the supply of spare parts.”

www.landia.co.uk