Latest News

Teledyne FLIR Launches Prism Supervisor Software, Enhances UAS Autonomous Capabilities

AI-Based Automated Response at the Edge Improves Drone Mission Safety and Performance. Goleta, CA, – Teledyne FLIR OEM, part of Teledyne Technologies Incorporated, today announced the release of Prism™ Supervisor, the latest addition to its Prism embedded software ecosystem. Prism Supervisor integrates drone autopilot flight control systems with real-time, AI-based observations at the edge to improve mission safety, efficiency, and performance, enhancing the capabilities of unmanned aircraft systems (UAS).

Prism Supervisor software empowers mission planners with a flexible programming framework and software development kit (SDK) to facilitate custom, intricate mission scenarios. During flight, Prism Supervisor adapts its autopilot functionality in real-time, dynamically generating mission segments and flight plans on the fly, minimizing operator impact while improving mission success.

For example, a Prism Supervisor-controlled UAV flying a search mission pattern can autonomously circle and alert the operator upon the detection of a human or threat. 1/2 "From behavior and mission planning to dynamically adjusting in-flight operations,

Prism Supervisor represents a significant advancement for drone autonomy through AI," said Dan Walker, Vice President of Product Management, Teledyne FLIR. "It improves operational performance via single-click missions, opening up new possibilities for UAS operation from commercial to military use cases."

Prism Supervisor simplifies the operator experience with a user-friendly graphic user interface (GUI) for mission planning, real-time mission visualization, and execution. Available for desktop or mobile deployment supporting Windows, Linux, macOS, iOS, and Android, the supervised mission management application streams and records detailed, full-frame-rate video, path visualization, and metadata. It can facilitate collaborative behaviors and synchronized mission execution among multiple unmanned aerial vehicles (UAVs). Prism Supervisor expands Teledyne FLIR's Prism digital ecosystem of advanced AI and image processing. It provides a platform for deploying object detection, tracking, and computational imaging on low-power processors, enhancing UAS mission performance and reducing development costs. For more information about Prism Supervisor and the entire Prism ecosystem, visit www.flir.com/prism.

Speedor Storm, the high-speed door ready for large external openings

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Hart Door System’s wind-resistant, high-speed, industrial rolling door, Speedor Storm, is ready for business be it a factory, warehouse, storage facility or any kind of plant operation that has one or more large external openings which must be opened frequently for people and traffic.

With wind resistance available up to ‘wind class 5’, as defined by DIN EN 12424, in the closed position this high-speed door is ready for openings to a maximum 8 metres width or height subject to 48 square metres.

The ability to withstand substantial wind pressure means major entrances open/close automatically so avoiding a less than optimal working environment and the escape of heated air.

Speedor Storm is designed specifically to help with several areas of business notably:

  • Productivity – because entering and leaving a building can be done rapidly.
  • Creating a better environment in which to work because of the high-speed operation, even on large doors means there are no unnecessary open periods.
  • Delivering maintenance of temperature and environment by door preventing penetration by wind born debris.
  • By saving on the substantial cost of heating – important as the cost of energy shows little sign of improving.
  • Low cost of ownership because this is a robust design and construction
  • Made in the UK at Hart’s Newcastle factory from where its teams of engineers are available throughout the UK for installation of Speedor Storms and reliable servicing and maintenance thereafter.
  • The benefits of Speedor Storms come from its unique guide system in combination with other carefully designed features.

Speedor Storm’s strength and wind resistance comes from its multi-layer PVC and textile, both long-lasting and tear-resistant and its inbuilt horizontal curtain braces and no external cumbersome and noisy external wind bars.

There is a colour choice as well as ‘a with or without vision panel ’ which combine to deliver a good appearance, operational effectiveness and a performance product.

Speedor Storm is in particular demand from waste processing plants and renewable energy facilities such as Anaerobic Digestion (AD) plants that produce energy from waste. The ability to limit the escape of odour and noise and prevent pests entering is highly valued by such companies. Speedor Storms have also proved to be a great asset for ports, notably for grain tipping bays.

Safety features are of course paramount, and here they include a state of the art safety light curtain, anti-fall protection and sensors to activate the door. There is a range of operating methods that include hands free, floor loops, radar, photo beam, radio operation, movement sensors, handheld or vehicle-mounted radio transmitters,  or simple push button and pull cords.

The automatic operation can be set to include or exclude pedestrians as desired. If warning lights or klaxons are required, these can be incorporated in a complete door system and control panel which are designed for any conceivable need including integration into a Building Management System if necessary. This is delivered via its unique guide system in combination with other carefully designed features.

Little wonder Speedor Storms are so highly regarded.

www.hartdoors.com

Enerpac Announces Fast Retraction RC-Trio Hydraulic Cylinders

Enerpac announces the RC-Trio hydraulic cylinders range featuring a enhanced durability bearing system and hybrid spring-return system for up to 3x faster retraction. The general purpose RC-Trio range is the latest evolution of the Enerpac RC-Series cylinders; the company’s most popular cylinder and used every day in thousands of engineering and construction projects.

Durability
The driving force of the Enerpac RC-Trio cylinder range is the new Trio bearing system. The system includes up to four high-performance wear bands, offering increased resistance to damage, reduced bearing load, and longer cylinder lifespan. The hardened composite material of these bands increases bearing surface area for greater side load resistance, significantly improving cylinder life. Durability is also on display in new high-performance polyethylene seals that last longer than ever. 

Another part of the Trio bearing system is the Trio stop ring, which includes an additional wear band to absorb greater side load. The stop ring can take full cylinder extension force and, depending upon cylinder size, is manufactured in Nitrided Steel or High-Resistance Bronze, for increased durability. It also features a durable wiper to help prevent contamination from entering the cylinder during retract cycles.

Productivity
To enhance productivity, the RC-Trio features a new Trio spring system designed to reduce retraction time. This pre-tensioned return spring system provides up to 3X faster retraction (available on 50-, 75-, and 100-ton models). It uses high-strength steel wire to improve spring life. The spring retention design improves serviceability, while allowing higher pre-load during assembly. Additionally, the spring is easily removed without special tools.

Versatility
The RC-Trio is a general-purpose cylinder available in 41 models and is designed for use in all positions. Versatile features include collar and plunger threads and base mounting holes that enable easy fixturing (on most models), new base holes on 30- and 75-ton models, hardened plunger saddle that protects plunger end during all lifting operations, and optional tilt and smooth saddles as accessories. Plus, the RC-Trio maintains the same dimensions and connection threads, providing full compatibility with existing RC-Series units in the field.

To learn more about the Enerpac RC-Trio cylinder range, visit www.enerpac.com

 

The differences between low and high concentrations of H2S gas

Hydrogen sulfide (H2S) gas can be fatal at high concentrations. But even low concentrations can cause health issues, particularly with prolonged exposure. So how can you best protect workers and minimise downtime? We answer your common questions about H2S.

What is H2S gas?

Hydrogen sulfide is a highly flammable, toxic and corrosive gas found in several industries including oil and gas, wastewater and chemical processing. It’s sometimes called ‘sour gas’, ‘sewer gas’ or ‘stink damp’ because of the way it smells like rotten eggs. However, H2S can’t reliably be detected by smell as it quickly deadens the sense of smell (a process known as ‘olfactory desensitisation or fatigue’).

How dangerous is H2S?

Exposure to high levels of H2S can be fatal, leading to loss of breathing, coma, seizures and death. It’s the second most common cause of fatal gas inhalation exposure in the workplace, second only to carbon monoxide[1].

But H2S can also be harmful at low concentration levels, causing headaches, dizziness, nausea, breathing difficulties and a sore throat. These health impacts can become more serious with prolonged exposure.

Low concentration vs. high concentration H2S – exposure limits

The health impacts of H2S depend on how much is inhaled and for how long. The recommended exposure limit set by NIOSH (the US National Institute for Occupational Safety and Health) for ten minutes is 10 ppm[2]

However, some U.S. states have developed ambient air standards for H2S well below OSHA and NIOSH standards due to concerns about health risks from chronic exposure[3].

For longer exposures to H2S, the recommended limits are a lot lower. For example, if you’re exposed for up to 24 hours, the World Health Organisation (WHO) recommends a maximum exposure of 0.1 ppm.

In response to concerns about the risks of H2S to human health even at low concentration levels, some countries have introduced equally stringent guidelines requiring businesses to monitor H₂S at such concentrations. That’s why we’ve recently updated our ALTAIR io™ 4 Connected Gas Detector, offering the option of a low-concentration hydrogen sulfide sensor that can detect H2S at very low levels*.

H2S in industry – the different sector impacts

H2S creates safety challenges for many industries. But some industries are more likely to be affected. These include:

Oil, Gas & Petrochemical (OGP)

OGP facilities handle raw ‘sour’ gas and oil which are naturally high in H2S. Extraction and refining processes release H2S, which may accumulate in confined, poorly ventilated spaces like processing units, pipelines and storage tanks. Closed systems with high-pressure conditions amplify the risks for workers.

Balancing safety and operational efficiency is an ongoing challenge in the OGP industry. Some are tackling this challenge by integrating new technological solutions into their safety management practices.

Waste water management

Wastewater facilities such as closed pipelines and sludge tanks have low oxygen levels and so provide the ideal conditions for H2S buildup. This is because sulfate-reducing bacteria which break down organic material and produce H₂S as a byproduct thrive in anaerobic (low-oxygen) conditions.

One of the key risks for waste water workers is when they’re entering confined spaces like tanks and sewer lines. For many waste water management businesses, real-time monitoring of gas levels is considered a must-have.

Steel production

The steel industry’s use of high-temperature processes and sulfur-rich materials can lead to the release of H2S, creating hazards for workers. Confined, poorly ventilated spaces and desulfurisation units pose particular risks. 


 

[1] Guidotti TL, 2010. Hydrogen sulfide: Advances in understanding human toxicity. Int. J. Toxicol 29, 569–581. [DOI] [PubMed] [Google Scholar][Ref list]

[2] https://www.cdc.gov/niosh/npg/npgd0337.html

[3] https://ohsonline.com/articles/2007/10/human-health-effects-from-exposure-to-lowlevel-concentrations-of-hydrogen-sulfide.aspx

Fish waste becomes fuel with Borger Multicrusher

A Borger Multicrusher has been installed at a cement manufacturer to chop up fish remains that are used as part of the fuel to fire furnaces.

The Multicrusher’s interconnecting cutting blades (set on a hexagonal carrier shaft) handle the 20% dissolved solids material to ensure that the fish remains (predominantly bones) are chopped efficiently so that they can be incinerated effectively.

Based on the principle of the Borger Rotary Lobe Pump, the Multicrusher has blades (instead of rotating lobes); configured for optimum chopping yields, that continuously macerate fish waste that would otherwise be economically unviable.

Using basic tools, maintenance staff at the cement plant can easily service the Multicrusher, without dismantling any pipe or drive systems. Designed with a quick-release cover to access wear parts, the Multicrusher benefits from Borger’s renowned Maintenance-In-Place design.

Borger UK

01902 798 977

www.boerger.com

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Setting New Standards in the Machining of Long and Heavy Workpieces – Nagel Vertical Honing Machines VL 15 and VL 30

Nagel introduces the high-performance vertical honing machines VL 15 and VL 30, designed specifically for machining long steel tubes, piston rods, and other heavy workpieces with standard lengths of up to 3,800 mm and diameters of up to 350 mm. Custom stroke lengths are also available upon thorough evaluation. These machines establish new benchmarks in precision and machining efficiency.

The Nagel VL series combines user-friendly operation, powerful drives, and a stable, robust design. Installed over a working trench, the machines enable workpieces to be accessed both above and below floor level. This ensures ground-level accessibility to the working areas, enhancing workshop flexibility.

With the VL 15 and VL 30, high material removal rates can be achieved in short cycle times while maintaining tight dimensional tolerances and geometrically precise bore shapes. These machines also deliver exceptional surface finishes, even on workpieces with rough pre-machining, meeting the stringent quality demands of various industries.

The VL series is also suitable for external machining, where the workpiece is mounted on the honing spindle, which performs both vertical and radial honing movements. This significantly extends the lifespan of sleeves and sealing elements, as the machining marks are oriented axially.

Equipped with an advanced automatic measurement system, the machines

achieve shut-off accuracy of 0.01 mm, even when machining long tubes with material allowances of up to 1.0 mm. This ensures consistently high manufacturing quality while minimizing operator effort.

Nagel honing machines are indispensable for companies prioritizing top precision and efficiency. The compact design of the VL series saves valuable floor space while delivering the stability required for machining large and heavy workpieces. They are the perfect solution for industries relying on cutting-edge technology in heavy machining.

With the VL 15 and VL 30 vertical honing machines, Nagel offers a forward-thinking solution that not only enhances production quality but also reduces production costs—a clear competitive advantage in an increasingly demanding market.

www.nagel.com

  

 

FS-Elliott Expands FSE-TurboCool® Lubricants and Additives to Elevate Centrifugal Compressor Performance

FS-Elliott Co., LLC, a leading manufacturer of oil-free centrifugal air and gas compressors, is proud to announce the launch of its expanded line of FSE-TurboCool premium lubricants and additives. These advanced solutions are designed to enhance lubrication, improve performance, and extend the life of centrifugal compressors, meeting the evolving needs of operators worldwide.

The expanded FSE-TurboCool line includes:

  • FSE-TurboCool 32 & FSE-TurboCool 46: Advanced synthetic lubricants formulated with a gas-to-liquids process that offer superior wear protection, minimize sludge and deposits, and perform well under extreme conditions. These lubricants extend compressor life and reduce maintenance costs, ensuring dependable operation.
  • FSE-TurboCool PG: Eco-friendly polyglycerol-based lubricant that resists varnish formation and provides long-lasting performance in demanding environments. This formulation reduces wear and buildup, supporting consistent efficiency and reducing interruptions.
  • FSE-TurboCool FG: Premium mineral oil meets high purity standards for industries like food processing and pharmaceuticals. NSF H-1 compliant and FDA-approved for incidental food contact, FSE-TurboCool FG is non-toxic, colorless, odorless, and tasteless, ensuring safety and stability.
  • FSE-TurboCool CC: Synthetic additive that enhances the solvency of hydrocarbon-based lubricants such as TurboCool 32 or 46. It reduces varnish formation and oxidative instability, cleans metal surfaces, and revitalizes lubricants for extended performance.

“FS-Elliott’s expanded FSE-TurboCool product line reflects our commitment to delivering innovative, high-quality solutions that meet the needs of compressor operators,” said Roger Beavans, Product Manager at FS-Elliott. “These lubricants and additives are engineered for peak performance and reliability, ensuring equipment operates efficiently and safely in any condition.”

The enhanced FSE-TurboCool formulations help operators achieve optimal performance, minimize downtime, and extend equipment lifespan. FS-Elliott remains dedicated to providing industry-leading solutions that operators trust for reliable, high-efficiency operations.

For more information on FSE-TurboCool lubricants and additives, visit https://www.fs-elliott.com/compressor-lubricants-additives.

FS-Elliott Co., LLC, a leading manufacturer of oil-free centrifugal air and gas compressors, is proud to announce the launch of its expanded line of FSE-TurboCool premium lubricants and additives. These advanced solutions are designed to enhance lubrication, improve performance, and extend the life of centrifugal compressors, meeting the evolving needs of operators worldwide.

The expanded FSE-TurboCool line includes:

  • FSE-TurboCool 32 & FSE-TurboCool 46: Advanced synthetic lubricants formulated with a gas-to-liquids process that offer superior wear protection, minimize sludge and deposits, and perform well under extreme conditions. These lubricants extend compressor life and reduce maintenance costs, ensuring dependable operation.
  • FSE-TurboCool PG: Eco-friendly polyglycerol-based lubricant that resists varnish formation and provides long-lasting performance in demanding environments. This formulation reduces wear and buildup, supporting consistent efficiency and reducing interruptions.
  • FSE-TurboCool FG: Premium mineral oil meets high purity standards for industries like food processing and pharmaceuticals. NSF H-1 compliant and FDA-approved for incidental food contact, FSE-TurboCool FG is non-toxic, colorless, odorless, and tasteless, ensuring safety and stability.
  • FSE-TurboCool CC: Synthetic additive that enhances the solvency of hydrocarbon-based lubricants such as TurboCool 32 or 46. It reduces varnish formation and oxidative instability, cleans metal surfaces, and revitalizes lubricants for extended performance.

“FS-Elliott’s expanded FSE-TurboCool product line reflects our commitment to delivering innovative, high-quality solutions that meet the needs of compressor operators,” said Roger Beavans, Product Manager at FS-Elliott. “These lubricants and additives are engineered for peak performance and reliability, ensuring equipment operates efficiently and safely in any condition.”

The enhanced FSE-TurboCool formulations help operators achieve optimal performance, minimize downtime, and extend equipment lifespan. FS-Elliott remains dedicated to providing industry-leading solutions that operators trust for reliable, high-efficiency operations.

For more information on FSE-TurboCool lubricants and additives, visit https://www.fs-elliott.com/compressor-lubricants-additives.

Brady reimagines 76mm core label printing

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Identification specialist Brady Corporation’s new BradyPrinter i7500 for 76mm core label rolls automatically adjusts all of its settings when new consumables are loaded. Ready to print in just 40 seconds, the printer also removes all calibration waste by printing the first label right. Set up, don’t touch? The approach in most industries to high volume, high precision thermal heat transfer 76mm core (3’’ core) label printing to date has almost always been “set it up and don’t touch”. Crucial for traceability and compliance, yet excruciating to set up and calibrate, the 76mm core label printing experience has been a notorious pain point for many manufacturing, electronics, electrical and laboratory industries. Ready in 40 seconds Not anymore. In a new proprietary printer model, global identification specialist Brady Corporation removed all label printing hassle to redefine the 76mm core label experience. “The new BradyPrinter i7500 does not require users to adjust sensors, heat settings, define label dimensions or waste labels in calibration”, says Ömer Adisen, Product Manager benchtop printers & software at Brady Corporation. “We call it LabelSense. The technology reduces the frustrating trial and error 1/3 www.bradyeurope.com of manual printer calibration to print readiness in just 40 seconds.

That includes loading Brady consumables, designed so they can only be loaded the right way.” Efficient, flexible printing The new BradyPrinter i7500 with LabelSense technology makes high precision 76mm core label printing a lot more intuitive, and efficient. There is no need to maintain multiple printers just to avoid the classic consumable and calibration hassle. “All optimal settings are already preloaded and the printer automatically recognises every Brady consumable. The i7500 offers considerable print flexibility by enabling users to switch from printed circuit board labels to rating plates, raised profile labels and cable sleeves, or between relevant specialised laboratory labels, in just 40 seconds.

Even when loading the tiniest 3.18mm QR-coded labels, the i7500 prints the first label right, reducing waste and supporting sustainable label printing practices.” Open core In addition to auto-calibration, the BradyPrinter i7500 can print 76mm core labels from any manufacturer in manual mode. “When considering a switch to the new label printing experience provided by the BradyPrinter i7500, there is no need to devalue current label stock. The BradyPrinter i7500 can print any 76mm core labels, from any manufacturer, with great speed and precision.” ©2022 Brady Worldwide Inc. 2/3 Software compatible When combined with Brady Workstation label design, the software instantly recognises the dimensions of loaded Brady consumables for fast and intuitive label creation. Next to label design protection, Brady Workstation also includes an easy scan to print app and a data automation app to print labels at the right time with the right ERP-system data. The BradyPrinter i7500 supports print languages like ZPL, and can print labels via other label design software. Premium printing redefined “The new BradyPrinter i7500 defines a new premium high precision printing experience for 76mm core labels”, Ömer says. “Fully automated calibration enables printing on different consumables within 40 seconds. Supported by a clear user interface on a large on-board screen, the i7500 prints a wide range of labels without any hassle. We can provide a hands-on demo at your premises to show your teams just how intuitive label printing can be.” For more information, contact Brady via This email address is being protected from spambots. You need JavaScript enabled to view it., or visit www.bradyeurope.com

FLIR: First choice for security at Intersec 2025

FLIR will highlight its industry-leading security and safety solutions at Intersec 2025 (Dubai World Trade
Centre, 14-16 January), specifically focusing on visible cameras, thermal cameras and radar systems for use
in challenging environmental conditions and applications. Whether it is 24/7 perimeter monitoring, long
distance intrusion detection or fire protection, visitors to Booth SA H11 will discover that FLIR has the optimal
solution.

FLIR Securities Intersec tradeshow Banners

A case in point is the FLIR Quasar Premium Bullet AI digital visual camera for the intelligent monitoring of
outdoor sites in demanding environments. The Quasar Premium Bullet AI captures critical evidential and
forensic video in 5 MP or 4K Ultra HD. Notably, it integrates FLIR Deep Neural Network (DNN) based Edge
AI video analytics to detect and accurately classify humans and vehicles, while the adoption of FLIR Nexus
enables object geo-tracking.
 
FC Series AI main image
 
FLIR Nexus brings edge communication to FLIR security solutions, allowing users to monitor activities in real
time. This seamless connection permits FLIR devices to communicate with each other, ensuring the end-to
end detection and tracking of targets.
 
Nexus logo final pos
 
Also in the spotlight at Intersec 2025 will be another 5 MP network camera, the FLIR Quasar Premium Mini
Dome AI. This discreet surveillance camera utilises high-end cybersecurity safeguards, providing advanced
AI, video analytics and situational awareness in challenging operation conditions.

Another technology prominent on the booth of FLIR will be thermal security cameras. Thermal cameras excel
in challenging conditions like fog, dust and complete darkness, making them ideal for 24/7 perimeter
monitoring and long-distance intrusion detection.

Thermal imaging solutions on display are set to include the FC-Series AI-R thermal radiometric camera for
the detection of hot spots and combustion risks in harsh outdoor environments and remote areas. Upon
detecting a significant temperature change, the camera promptly sends an alarm to the Video Management
System (VMS) for swift deployment of response tactics. FLIR’s United VMS, which supports pan/tilt/zoom
(PTZ) tracking, offers enhanced cybersecurity, analytics and integration with third-party systems.
Elsewhere on the booth, visitors will discover the FLIR FC-Series AI thermal analytics security camera: a
reliable, cost-effective way to protect perimeters from intrusion. AI analytics capability enhances situational
awareness and incident detection, enabling users to make informed response decisions.
 
FH Series R PTZ
 

Also at Intersec will be the FLIR FH-Series R multi-spectral fixed camera for early fire detection, which
integrates thermal imaging with 4K visible imaging to provide rapid visual verification of hot spots before they
ignite. This technology is particularly useful in industrial facilities, warehouses and fuel storage areas. Show
visitors will also be able to see a model from the same product family, the FLIR FH-Series R PTZ, which
offers fixed pan-tilt-zoom capabilities.


From a radar perspective, FLIR has plenty to offer. Advanced radar solutions, available in both long-range
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and short-range options, offer the precise detection and tracking of objects such as people and vehicles,
making them particularly effective for perimeter security.


At Intersec, FLIR is set to showcase its Elara R-290 compact commercial ground radar for the early detection
and warning of intruders. Radars can track targets in all weather and lighting conditions, offering position
intelligence via dynamic mapping of humans (200m range) and vehicles (400m range) in real time.
Incorporating advanced imaging and radar solutions can be a game-changer for any security, safety or fire
protection project. However, true customer advantage and added value requires more than the deployment
of technology alone. It requires a strategic combination of expertise, cutting-edge technology, innovation and
forward-thinking vision. This is where FLIR excels, as visitors to the booth at Intersec 2025 will discover
when they engage with FLIR’s friendly team of expert professionals.



Fast spill response with improved Rigid-Lock QuickBerm Lite

Protect your environment with the efficient, space-saving spill containment berm from Brady. Its patented Rigid-lock design ensures quick deployment and easy setup, what makes it ideal for fast spill response.

Benefits:

  • The sturdy, portable berm offers 100% leakproof containment, making it ideal for a wide range of spill prevention needs
  • Save time and effort with our one-piece design
  • The exclusive wall support system features durable stainless-steel braces that securely lock into place at a 90-degree angle
  • The reliable containment system features robust walls and anchor points that can withstand 64 KPH (40 MPH) winds, preventing the berm from moving into the stowed position
  • The PVC-coated fabric is highly resistant to ultraviolet rays and chemicals, ensuring long-lasting performance even with repeated use

Check-out available dimensions >>

Brady Corporation
www.brady.eu

The Hills Are Alive with the Sound-Thinking of Sustainability

As the saying goes: ‘Don’t judge a book by its cover’. A partly submerged tank containing a chopper pump and a mixer at Hendwr Farm’s biogas plant probably won’t win any industry awards in the ‘aesthetically pleasing’ category. But who cares? Least of all, Phil Hughes, who runs it.

A traditional hill farm in North Wales that produces lamb and beef? Yes. A highly innovative visionary business that leads the way in diversification by taking a truly circular view of its future? Ditto.

The farm (about 25 miles west of Wrexham) began in 1902, when it was purchased by Phil’s great grandfather, Cadwalader Jones Hughes.

‘Diversification’ is of course a big current buzz word, and good job too, but John Hughes (Phil’s father), saw the benefits of it back in the late 1960’s when he began offering camping at the farm, which then evolved into the thriving Hendwr Caravan Holiday Park. Income from the serenely-set medium-sized static caravan holiday park was and continues to be a success, but its growth meant plenty of electricity consumption, so as the next Hughes’ generation brought its influence to bear, Phil (in 2011) went ahead with the introduction of ground-mounted solar panels.

“We wanted to limit external inputs into the farm,” he said, “and when we saw the benefits of this first venture into renewable energy, we started looking at how else we could expand it.”

Producing a modest amount of manure from 120 Angus calves, a plan emerged to combine this with waste, corn and chaff to feed a biogas plant that would not only produce energy, but fertiliser too, which especially given the rising costs, the farm didn’t really want to have to buy any more. The key ingredient though would be to use chicken litter, which has proved to be a very fast and efficient feedstock.

‘Strong financial case for making this source of renewable energy work’

“I would say that when we started building our biogas plant in 2015, we were gloriously ignorant,” added Phil Hughes. “It was a thousand times harder than we thought it would be! – but when you look at the value of farm produce compared to the value of anaerobic digestion (AD), there’s a strong financial case for making this source of renewable energy work and work well. Food is so undervalued. We’re incentivized as farmers to produce food as cheaply as possible, rather than look at the whole food cost and the effect on land and our wider society.

“We have almost 100 control signals on our biogas process, so if something isn’t right and an alarm goes off (typically in the middle of the night!) you have to deal with it straight away if you want to keep the plant up at its target performance levels, which for us, is a minimum of 95%. We have a 200kW engine, and a digester that very much fits our farm size. I’ll admit that we’re obsessive about maintenance, but we have to hit high numbers to be profitable, and you just can’t neglect the biological process. It’s not like a light that you switch straight on. It takes time to come back to full production, so time is money. To keep our system running at its optimum levels, we’re always absolutely on it. We take regular samples, and over the years have learned what good biology is, so that we know what to do and what not to do.”

For its 90m3 reception tank, Hendwr invested in a chopper pump and a mixer from Landia to blend the incoming feedstock into a very homogenous mix.

“The only problem we had,” continued Phil, “is that after six years of continuous use, we eventually killed the pump! It was cast iron and was basically being asked to do something that it wasn’t designed for. The low pH, running at 3.8, had over time, made everything corrode. We very much wanted to stay with Landia, but to upgrade to stainless steel, this meant a short wait, so they kindly helped us out with a temporary replacement so that we could keep producing gas. The Landia Chopper pump is very effective and reliable, continuously reducing particle sizes, ready for the liquid to go through into our milling and micronizing lines.”

During lockdown when some of us put on far too much weight and drank far too much, Hendwr far more wisely relieved the boredom by learning how to dewater digestate and slurry to get not only a dry, stackable solid, but a polished water that’s dischargeable into water courses. This has resulted in the development of Ekogea, whose BioComplex product maximises biogas outputs and improves commercial viability, as well as reducing waste digestate by up to 80% by volume. It also treats wastewater to Environment Agency permitted discharge standards. The product range helps with sustainable and profitable slurry management, provides natural fertiliser for crops and soil regeneration, and improves the health and profitability of livestock.

Phil Hughes continued: “We’ve found a way of concentrating solids so that we can now dewater very efficiently. As hill farmers, it allows us to take that digestate as valuable fertilizer safely up onto the banks, whereas slurry tankers would be dangerous with all that weight sloshing around. It’s a big advantage because we can deliver nutrients much further through the farm, which has increased our productivity. When spreading onto our land, it’s going into the plant, instead of going up into the air, which is why we're growing so much more grass on the farm, because the nitrogen isn’t being been lost to the atmosphere.

“We’re actually reducing the volumes of liquids and slurries we’re dealing with by a factor of almost 10, reusing the water to wet the dry chicken litter at the front end of our system for a much cheaper, more efficient process. When trying to dewater, covering our lagoon (5m deep), was one of the best things I ever did. We have no shortage of rain in North Wales! Dewatering offers numerous options because it is so much easier to transport. It is a very exciting piece of technology, which in addition to farming, can be used at factory sites, even if they already have a DAF treatment process. We can collapse the COD, BOD and nitrogen levels that they get charged for by the water companies.

‘Good Mixing Remains Crucial’

He continued: “At the heart of our biogas process, good mixing and pumping for that all important homogenization remains crucial. When the Landia team turn up to carry out maintenance, they are armed with good client data. We could be made to feel that we’re just a small customer out of thousands, but they know our names, know exactly what they are doing and provide very attentive, enthusiastic service. They’re good lads. Hitting our performance target means having the right machines, the right service, and the right after-sales, which we’ve always had from Landia.”

01948 661 200

This email address is being protected from spambots. You need JavaScript enabled to view it.

www.landia.co.uk

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