Latest Case Studies & White Papers

Switch from oil to liquid gas serves up big savings for Tracklements

Leading British condiments maker, Tracklements, has boosted its production capacity and enhanced its environmental credentials by switching its energy supply from oil to liquid gas from Flogas. The move to modern, efficient liquid gas-fired Fulton VSRT steam boilers is expected to cut the company’s costs by a significant 21%, whilst also reducing carbon emissions by almost 25% and nitrous oxide (NOx) levels by 75%.

The Wiltshire-based company has been making condiments for more than 50 years and has an extensive range of over 60 artisan products, from mustards, ketchups and sauces to pickles, chutneys, jams and jellies. All ‘handmade in small batches’ using natural ingredients, these are made in unique jacketed steam cooking pans that mimic traditional homemade methods, and for the last 40 years they have been powered by two Kerosene oil-fired steam boilers.

“We needed to increase our steam capacity to support the continued growth of the business,” said Ben Read, Operations Director at Tracklements. “But we’re also fully committed to improving our environmental footprint, so we wanted to move away from the higher carbon footprint which oil represents. By replacing our ageing oil-fired steam boilers with the latest liquid gas-fired VSRT models we’ve not only increased our steam capacity by 100%, but we’ve also cut costs and significantly reduced our carbon emissions in the process. This was a major factor in our decision, as Tracklements continues to work tirelessly towards our goal of planet-friendly products.”

Having worked with Fulton for over 40 years, Tracklements looked to them to specify a cutting-edge system that would help minimise its environmental impact. Fulton also recommended Flogas as a liquid gas supplier – one that could provide a reliable supply and trusted on-going service. Flogas and Fulton partnered to deliver Tracklements a full turnkey, end-to-end energy solution that also included all necessary ancillary equipment as well as service and training contracts.

Commenting on the project, Jeff Byrne, aftercare and business development manager at Fulton said: “By modernising their steam raising equipment and changing their fuel type to liquid gas, Tracklements can expect an impressive 21% financial saving and a near 25% reduction in carbon emissions. These cost savings are based on current gas oil prices before the planned withdrawal of tax relief on red diesel in April 2022, so looking forward they’re actually far more favourable. Cost and carbon savings can also significantly increase by up to 30% when combined with the potential steam system efficiency savings by running the latest fully-modulating, high-turndown liquid gas boilers. What’s more, our liquid gas-fired VSRTs will help minimise other pollutants, with NOx levels projected to reduce by 75% compared to the previous oil-fired steam boilers.”

Tracklements has a strong environmental policy and holds ISO 14001 certification for its green credentials. “We’re constantly looking at ways we can enhance efficiencies and minimise the environmental impact of our artisan manufacturing process,” continued Ben Read. “We’re really glad to have now made a great step in that direction. Liquid gas is also more reliable for our business. Our tanks are fitted with auto-ordering technology, so as soon as they hit 40%, it triggers a re-order. It’s great peace of mind and leaves us able to focus on making great green condiments.”

Jude Hurley, Business Energy Manager at Flogas added, “This is a great example of how a simple switch from oil to liquid gas can have a major impact, logistically, financially and environmentally. Not only will the company benefit from a more efficient, reliable fuel with fewer emissions, but it is also setting itself up perfectly for a seamless transition to renewable green gas in the future. Bio-propane is chemically identical to liquid gas, so when the time comes for Tracklements to become carbon neutral, it can be simply dropped in without any changes to equipment or infrastructure. It’s an energy solution that’s truly fit for the future.”

Flogas Britain Ltd

As ‘Experts in Energy’, Flogas has more than 35 years’ experience in providing tailored energy solutions to commercial, industrial and domestic customers across the UK. From Liquefied Petroleum Gas and Liquefied Natural Gas to propane enrichment of biomethane – the company delivers high-performance, reliable, cost-effective energy solutions to suit customers' exact needs.  www.flogas.co.uk/business

Tracklements

Based in the heart of Wiltshire, Tracklements has been making award-winning artisan condiments for over 50 years. Along with chutneys, relishes, pickles and sauces, The Tracklements range includes ketchups, jellies, salsas, mustards, fruit cheeses and Charcuteriments. It uses only the very best quality, natural ingredients, and works with British famers and spice growers from all around the globe to ensure the Tracklements products taste as good as the best homemade versions. For more information visit www.tracklements.co.uk

Fulton Limited

With manufacturing facilities in the United States, Great Britain and China, Fulton is a global manufacturer of steam, hydronic and thermal fluid heat transfer systems. Backed by over 60 years of research, innovation and experience, Fulton is building on a tradition of success and is focused on improving life through heat transfer solutions. For additional information about Fulton please visit www.fulton.co.uk.

Designing a Switchboard for a Fishing Trawler

Author: Mark Guest - Product Manager for Power Distribution Systems

When NU-Design Limited, a marine electrical services business based in Peterhead, Aberdeenshire, Scotland needed help in the designing of a very specific control centre specification, the company’s engineers contacted Rittal UK to design a marine switchboard for a distribution and motor control centre (MCC) to be installed in a new Scottish trawler, the Endeavour V. 

The Challenge:

The Endeavor V is a Bureau Veritas +1A1 fishing vessel, she was designed by Macduff Shipyards Ltd. While the hull of the boat was built at Finomar shipyard, Szczecin, Poland.  The MCC panels feed-out to all the electric motors onboard the vessel, the main switchboard feeds-out to both the 415V distribution boards and the 415/230V transformers, which in turn feeds into the applications on board the commercial vessel. 

Bostik provides vital repair solutions in international yacht race Event stand used to launch Born2Bond™ MRO range

Bostik adhesives, including solutions from its Born2Bond™ Engineering Adhesives range, comprise an integral part of a vital Repair Kit or ‘Kit à partir’ that was offered by Arkema, Lalou Multi and Bostik to all 79 teams in the Transat Jacques Vabre (TJV) multi-day yacht race.

The adhesives have been chosen for their fast-curing, high-strength, and optimum moisture, humidity and chemical resistance qualities, crucial for the rigours of a global sea challenge.

The Repair Kit, is used in the event of any equipment failure, delivering a more sustainable maintenance approach than replacing entire parts. The kit provides the required range of fast, instant, and primer-free structural adhesives, sealants and lubricants, with anti-corrosive and hydrophobic qualities suitable for underwater and minute-size applications.

Arkema, a major specialty materials company and Bostik’s parent company, is the headline sponsor of the Arkema 4 Ocean Fifty trimaran, one of the yachts competing in the TJV race. It also has an exhibition stand in the event village, focusing on ‘Energy, Sport and Preservation of Resources’.

New CompAir white paper outlines why food and beverage manufacturers should opt for oil-free compressors

CompAir has published a new white paper for the food and beverage industry, discussing how the right compressed air system can make an important contribution to an organisation’s overall sustainability ambitions, as well as help protect the environment.

Available to download for free from https://www.compair.com/en-gb/industries-and-applications/food-and-beverage, the white paper considers how oil-free compressor technologies can help secure a competitive advantage for food and drink manufacturers. Unlike compressed air usage in other industries, there are no standards or legislation that define an acceptable minimum purity level for compressed air used in food manufacture. While regulations and codes around the world state that compressed air used in this environment must be contaminant-free and pose no risk, no actual limits are stipulated.

The risk to food and drink from compressed air processes can potentially be significant if the right precautions and preventative measures have not been taken. Moisture, oil and other particles all pose a risk in applications where compressed air is commonly used, such as drying and filtering.

Ultimo and Good Solutions partner to integrate production and maintenance

Ultimo and Good Solutions enter a technology partnership to help customers improve production efficiency in factories. Based in Sweden, Good Solutions develops and operates software designed to increase factory profitability and sustainability. Ultimo is a leading Enterprise Asset Management (EAM) solution supplier in Europe, with a strong focus on manufacturing. The partnership combines EAM and Overall Equipment Effectiveness (OEE) software products, enabling asset-intensive companies to optimise machine output and reduce production costs.

RS Production OEE software from Good Solutions identifies production losses and acts as the operators’ eyes and ears. As soon as a loss, such as a deviation or a machine failure, is detected, the appropriate action is automatically created in Ultimo's Asset Management platform, enabling the issue to be resolved quickly and efficiently.

Vibration tests boost NASA’s electric aircraft project

Vibration tests prove to be a key milestone for NASA’s new X-57 “Maxwell”

USA, November 2021

To ensure NASA’s new X-57 “Maxwell” electric aircraft would be energy efficient and safe for use, NASA carried out extensive ground vibration tests, simulating the stresses it would experience during a real flight.

With the increasing demand for electric-powered ground transportation, NASA wanted to prove that an aircraft could also be electrically powered. The result is the X-57 “Maxwell” airplane, which - instead of the usual gasoline-powered motors - has two, all-electric motors powered by traction batteries.

To ensure the new design meets the criteria for energy efficiency and airworthiness, NASA’s experimental aircraft underwent multiple vibration tests and data from the accelerometers around the motor was collected on a LAN-XI data acquisition system and analyzer platform, provided by test and measurement expert, Hottinger Brüel & Kjær (HBK).

Following this, NASA’s engineers used HBK’s BK Connect software to test and analyze data from 191 test runs, with 14 different test configurations. The ground vibration test results gave NASA a much better understanding of the modal characteristics of the X-57, currently in the Mod II configuration.

Work on the new aircraft will continue, with the X-57 project team updating the model now they have the necessary data.

The full case study is available to read on HBK’s website: https://www.bksv.com/en/customers/space/nasa

New report reveals the enormous potential of Maintenance 4.0

Ultimo has published its 2021 Enterprise Asset Management Trend Report after conducting a major international survey. The report is based on the results of the largest survey of asset management professionals it has undertaken and includes data from the UK, Germany, Holland and Belgium. The report is available to download from www.ultimo.com/eam-trend-report

The report, labelled “insightful and inspiring” by Wim Vancauwenberghe the Maintenance Evangelist and Director of BEMAS, addresses the major EAM themes of Uptime, Cost Control, Efficiency, Safety, Investment, Education and Technology. Through the correlation of data, it reveals some powerful truths about the current state of the EAM sector but also the enormous financial potential for what Wim refers to as “Maintenance 4.0 and Asset Performance 4.0”.

Revelations in the report include – the number of facilities experiencing unplanned downtime per year, the average cost per hour of down time and the pressure that asset managers are under to balance profitability and safety.

New whitepaper shows why EAM is the road to higher availability and lower costs in the transportation sector

Ultimo has produced a new whitepaper to help asset managers in the transport industry leverage Enterprise Asset Management (EAM) technologies to gain better control over the cost, profit and risk associated with their fleet. The paper, titled EAM for fleet management and maintenance: the key to better profits in the transport sector, is available to download from www.ultimo.com/whitepapertransport. It aims to provide practical guidance on how managers can reduce the stress of optimising service and inspection of the fleet, reducing downtime, improving efficiency and meeting regulatory compliance.

“In the fleet management sector, uptime of vehicles is vital. They only make money when they are on the road, and the profit margins are already notoriously thin,” says Chris van den Belt, Team Leader Product Management, at Ultimo. “That’s why it’s vital that managers have access to real-time operational data, so they can carry out timely maintenance and investment to protect availability and reduce the risk of costly breakdowns and accidents.”

The whitepaper explores various factors affecting availability and cost control for transport businesses, discussing the importance of achieving optimal uptime while avoiding the costly practice of over-maintaining vehicles.

It then outlines how EAM software can help managers gain better control over their fleet assets by improving maintenance efficiency, enabling more productive remote operation, and simplifying how vital HSE processes are managed.

Ultimo’s EAM platform chosen as one of the technologies of the future for MTC’s Digital Manufacturing Accelerator (DMA)

Ultimo has been chosen to showcase how its Enterprise Asset Management (EAM) technology helps realise the factory of the future at the Digital Manufacturing Accelerator (DMA). The initiative, by the Manufacturing Technology Centre (MTC), lets manufacturers experience the advantages of industry 4.0, IoT, smart manufacturing, robotics, and automation in real life and see how leveraging these technologies can transform the factory environment. As part of the project, MTC will build a state-of-the-art re-configurable factory in the centre of Liverpool to house the technologies.

EZ Factory and Ultimo partner to help manufacturers align technical and production departments

Enterprise Asset Management (EAM) solution provider Ultimo and digitalisation specialist EZ Factory have agreed on a partnership that helps manufacturing companies improve communication between their technical and production departments. EZ Factory’s EZ-GO platform digitises many of the standardised work processes relating to safety, quality, training and efficiency, empowering operators to drive continuous improvement​. Ultimo’s EAM cloud platform supports organisations with asset management by improving labour productivity, maximising asset availability, and increasing safety on the shop floor. The integration of the Ultimo and EZ Factory platforms helps deliver an integrated approach to operations and maintenance, improving communication and teamwork for easier and more efficient processes.

BREWERY HAS NO REGRETS FOLLOWING REBLLIOUS MOVE FROM STEAM TO THERMAL FLUID

In 2015, with business improving but original process equipment reaching end-of-life, Rebellion Beer Company bucked the trend and, with impartial advice from heat transfer specialist Fulton, replaced its ageing steam boiler for a thermal fluid system. Now, six years on, we approached Rebellion’s Mark Gloyens to update us on how brewery life has coped with the switch.

Anyone running a brewery will tell you just how critical the boil phase of the brewing process is; and when Rebellion set out on its journey from steam to thermal, they were warned that they’d never succeed in getting that clean flavour achieved from a steam-driven rolling boil.

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