IDCON founder, prolific author, and known as the 'Godfather of Reliability'

"MAINSTREAM is the world's most valuable Maintenance & Reliability Conference"

New research names twelve obstacles holding British industry back – from the retirement wave to a reactive culture nobody can break – as MAINSTREAM UK returns on 20–21 October.

When MAINSTREAM brought three decades of international maintenance and reliability expertise to British shores last October, more than 300 practitioners came to Birmingham. This year the event doubles: 500+ have already booked, and 95% of expo floor space was gone before the program was complete.

Behind that growth sits a body of research that has hardened. MAINSTREAM's 2026 UK study – drawn from surveys and roundtables – identifies twelve obstacles now defining the state of British and Irish industry. The most exposed nerve: 71% of respondents report no dedicated reliability engineering function at all.

The findings make uncomfortable reading. Reactive maintenance remains the dominant operating mode despite universal agreement that it is costly, unsafe and unsustainable. Practitioners describe maintenance as a "necessary evil" – celebrated when assets run, blamed when they fail, defunded when things are quiet. Obsolescence, not age, has emerged as the primary risk driver, with control system obsolescence creating multi-million-pound liabilities organisations keep deferring. The retirement wave has arrived, taking technical knowledge, asset history and operational judgement that exist nowhere in any system.

"The barrier is not knowledge," the research team notes. "It's culture, incentives and leadership continuity."

Two new themes were elevated this year: change management capability – the recognition that failure to sustain improvement is a people problem, not a technical one – and the absence of a documented long-term asset strategy, itself a root cause of much of the rest.

Every session addresses these themes directly. Headlining is Ed Van Cise, NASA's 78th Flight Director, on Maintenance and Reliability at the permanent Moon Base NASA is establishing at the lunar south pole – an environment whose obsolescence and spares problems mirror those on British factory floors. Drew Troyer, the highest-rated speaker of 2025, returns with his Data to Dollars framework for organisations that are data rich but information poor. Russell Raath, formerly of Harvard professor John Kotter's global consulting business, examines why strategies stall.

The UK and Irish contingent is formidable. United Utilities' Chief Maintenance Officer Phil White is joined by Emily-Jo Howarth (Southern Water), Sven Brown (Severn Trent), Ross McCorrisken (Scottish Water) and Gerald Doocey (Affinity Water). Richard Barber brings Drax Power Station's perspective, Damien O'Neill speaks for Biffa, and food manufacturing is represented by David Stephens (Premier Foods), Jo Gillard (Finsbury Foods) and Sam Smith (The Compleat Food Group). Dan Everest (Greater Anglia), James Ayre (East Midlands Airport), Jonathan Watkinson (Babcock), Garrett Fitzgerald (Eli Lilly, Ireland) and Audrey Kelleher (BioMarin) complete a cross-sector line-up.

The event delivers 70 case studies and sessions, six specialised tracks, six workshops, hands-on tutorials in the Education Pavilion, peer-to-peer Xchange sessions and a 50-partner expo, plus year-round MAINSTREAM Community membership and post-conference access to all content.

MAINSTREAM UK takes place 20–21 October 2026 in Birmingham. Full details at https://www.mainstreamcommunity.com/uk-summit/home

Newcastle-based Hart Doors reports strong demand for its high-performance industrial doors ranging from its of high-speed Speedor doors to its Typhoon range of high-performance shutters. “Demand is across the board and as a result we have had to increase working shifts. All our brands are attracting significant interest which has prompted us to take positive action,” says Hart’s managing director Nick Hart.

“We are a global business with a strong base of clients spread across the UK. By increasing shifts we have been able to continue to accommodate demand-driven growth. Further As Britain’s original manufacturer of the automatic high speed door “Speedor” , we have always led the way with developments in commercial door technology.

“We offer a comprehensive range of high speed roller shutter doors to suit a wide range of commercial applications, whether light internal use or heavy industrial use.

The Speedor high speed door is robustly engineered for frequent use in high-traffic situations. Our tried and tested vertical high speed doors can be used internally or externally to optimise traffic flow, improve working conditions and save energy.

Mr Hart adds: “Despite the recent holiday period demand for Speedor high speed doors, Typhoon and high level security doors was high. Such is the level of demand we have now started a two working shift pattern to keep up with client orders.

“Current examples of work include the production of six roller shutters to act as machine guards for a client to protect openings of between 3 and 7 meters in width. In addition, we are at the final stages of handing over a High security roller “SR4 security door” being installed in a bank in Kuwait.”

Only recently Hart introduced a demonstration vehicle to accommodate the growing need for installations across the UK. “All in all we are seeing growth on all fronts and have a great team at our Newcastle headquarters,” says Mr Hart.

“We continue to emphasize that we are a specialist engineering company that specialises in the design and manufacture of a wide variety of door systems relevant to the challenges of everyday business. We resolve many issues within the built environmental and safety and security issues arising in many global sectors.

“Hart’s products are in daily use across over 30 countries world-wide in sectors such as aviation, energy from waste, infrastructure, food and beverage production as well as a host of manufacturing processes.

Of Hart’s many brands, it’s the internationally recognised Speedor range of high-speed doors that has become so successful in establishing Hart’s outstanding reputation. After all, a typical Speedor has on average a life expectancy with existing doors at 30 years plus and 1000,000 operational cycles in normal conditions. This attests to the quality of Hart’s engineering.

www. hartdoors.com

Standby power, fleet depots, marine terminals, industrial plant: different applications, the same testing problem.

Visual inspection has its limits. While it can identify obvious signs of deterioration such as coating breakdown, surface corrosion and staining, it cannot determine remaining wall thickness, weld integrity or the condition of internal surfaces. For many fuel tanks these hidden factors often represent the greatest risk.

This is where Non-Destructive Testing (NDT) provides value. Rather than relying solely on a visual inspection that cannot look deeper than the surface, NDT delivers measurable condition data that supports informed engineering decisions regarding maintenance, repair or replacement.

Tier 1: External Examination

Recommended annually for tanks.

This first level combines:

• Visual inspection of the tank external surfaces
• Ultrasonic Thickness (UT) measurements of the external surfaces
• Inspection of ancillary equipment, including pipework, vents, gauges and alarms

The objective is to establish a baseline condition assessment and identify potential areas of concern without interrupting normal tank operation.

Typically identifies:

• Surface corrosion
• Coating failure
• Equipment deterioration
• External metal loss

Tier 2: Targeted Assessment

Additional to Tier 1, a targeted inspection of known or suspected problem areas.

This level further enhances Tier 1 findings and focuses on locations commonly associated with accelerated deterioration, including:

• Lower shell sections
• Areas subject to increased external corrosion
• Accessible weld seams

Inspection techniques include:

• Detailed UT surveys
• Magnetic Particle Inspection (MPI) of welds

Typically identifies:

• Tank corrosion
• Localised thinning
• Weld cracking and defects
  
  

Tier 3: Full Internal Inspection

Tier 3 is the most comprehensive assessment available, encompassing Tiers 1 and 2, with the addition of the following inspection activities:

• Full internal visual inspection
• 100% MPI of internal welds
• Internal UT thickness testing
• Corrosion mapping

In order to carry out these inspections the tank must be:

• Taken out of service
• Cleaned internally
• Prepared for inspection
• Managed under confined-space procedures

This level provides a complete understanding of the tank's internal structural condition and potential remaining service life.

Additionally identifies:

• Internal pitting and corrosion
• Localised thinning
• Sub-surface defects within the welds
• Structural deterioration
• Weld cracking and defects

From Inspection to Asset Management

The true value of NDT lies not in a single inspection report, but in the ability to build a condition history over time.

Successive inspections provide evidence of:

• Corrosion progression rates and patterns
• Identification of any potential failure points
• Future maintenance requirements
• Remaining asset life

This data enables asset owners to make informed decisions rather than reactive ones.

Recommended Decision Path

Inspect → Monitor → Repair → Replace

Inspect - Regular visual inspections

Monitor – Identify and track problem areas

Repair – Carry out remedial works to restore integrity

Replace - Structural condition no longer supports continued operation or economic repair

Specification Matters

Where replacement is necessary, specification is critical.

OTS manufactures fully enclosed bunded steel fuel tanks designed and constructed to BS 799-5:2010, the recognised industry standard for steel oil storage tanks. In addition, OTS are also certified to manufacture to OFTEC OFS T200, which verifies the integrity and performance of the complete bunded tank system, providing clients with enhanced confidence in compliance, quality and environmental protection.

NDT is more than a compliance exercise. It provides the evidence required to manage risk, extend asset life where appropriate, and make informed decisions on repair, refurbishment or replacement before failure becomes a business, environmental or safety issue.

Better data. Better decisions. Safer assets.

For fuel tank NDT inspections or further information, contact OTS Group on 01386 853409 or visit otsgroup.co.uk.

Maintenance and engineering teams already capture huge volumes of asset, work order, inventory, and operational data. But turning that data into a confident decision is rarely straightforward as priorities shift; people change, and processes evolve. This often means unplanned failures, maintenance budgets that are harder to justify, and engineering knowledge that's difficult to scale across the business.

Agility AI, built into Aptean Agility Enterprise Asset Management (EAM), changes this. It closes the gap between data and decisions. Your team can ask questions in natural language and immediately get insights drawn from live asset, maintenance, and operational data. It flags anomalies and delivers answers in seconds.

Agility AI is shaped by feedback from ten early adopter customers and is built to interpret questions with precision. It resolves ambiguity by clarifying next steps, and demonstrates exactly how each answer is reached. This transparency, delivered through its Intelligence Trace capability, means your team can see the reasoning behind every response, so they can act with genuine confidence.

A common concern is that data needs to be perfect before AI can add value. In practice, the opposite is true. Agility AI's built-in Asset Intelligence Assessment shows exactly where your data needs attention and what to prioritise first, so you can start benefitting from AI while continuously improving the data behind it.

The results speak for themselves. Customers using Agility AI in production have already used it to surface early warning signs across sites, identify assets missing appropriate maintenance plans, and spend far less time exporting and interrogating reports, freeing up time to focus on the work that reduces downtime.

Come and see Agility AI for yourself. Visit us on Stand K8 at MAINSTREAM UK Summit or find out more at aptean.com.

Reliable machinery starts with accurate measurement. Easy-Laser® provides professional laser measurement and alignment systems designed to help maintenance and engineering teams work more accurately, efficiently and confidently.

From shaft alignment and geometric measurement to belt alignment and other precision applications our systems provide clear and intuitive measurement data that helps engineers identify problems, make accurate corrections and document their results.

Whether you are installing new machinery, carrying out routine maintenance or troubleshooting recurring problems, Easy-Laser® gives you the tools necessary to measure accurately and align correctly.

When it comes to making those final adjustments, our Precision Alignment Shims provide a high-quality practical solution. Manufactured from stainless steel and available in a comprehensive range of sizes and thicknesses, they are ex-stock in the UK and available for next-day dispatch.

Backed by UK-based calibration, technical support and specialist training Easy-Laser UK helps engineers get the job done right and keep machinery running reliably.

MEASURE ⇒ ALIGN ⇒ CORRECT ⇒ VERIFY

www.easylaser.com

Every EXAIR Safety Air Gun is engineered to be rugged enough to withstand a demanding industrial environment, yet comfortable enough to use for long periods of time. Each model includes one of EXAIR's engineered Air Nozzles. EXAIR Air Nozzles not only provide superior performance, but are also quieter and safer than other models on the market. For a limited time, you can receive a complimentary Model 6013SS High Velocity Air Jet with the purchase of any Safety Air Gun.
Our VariBlast® Precision Safety Air Gun is small and powerful while remaining light and ergonomic. Blowoff force can by adjusted by varying trigger pressure. The high impact, acetal body provides the durability needed for demanding industrial applications.
Our VariBlast® Compact Safety Air Gun is a lightweight, ergonomic gun that provides full-range variable blowoff force, based on trigger pressure. It is compatible with any of our 1/8 NPT engineered air nozzles and has a sturdy cast aluminum body with two inlets for optimal positioning.
The Soft Grip Safety Air Gun is our most popular gun. It is cast from sturdy aluminum with a comfortable four finger trigger to reduce fatigue over long periods of use. EXAIR offers a wide variety of 1/4 NPT engineered air nozzle options for light to heavy duty blowoff applications.
The Heavy Duty Safety Air Gun is the powerhouse you need for the harshest environments and stubborn blowoff applications. It is outfitted with our most powerful 3/8 NPT engineered air nozzles to provide the highest force needed for your application. The durable cast aluminum body includes an ergonomic composite rubber grip and wide curved trigger that makes it comfortable for hours of use without fatigue.
EXAIR's TurboBlast® Safety Air Gun can produce up to 23 lbs (10.4 kg) of strong blowoff power for large cleanup jobs. To reduce user fatigue during extended use, the rugged cast aluminum handle is wrapped by a sturdy, yet soft, elastomer grip and the low profile trigger is housed in the handle for easy-to-reach control. Select models also include an integral adjustable gate valve to allow for on-the-fly flow adjustment as needed. https://exair.co/190-sagpromo

• What each site has previously paid
• Which suppliers were used and what the contracted prices should be
• The latest internal purchase price
• Public marketplace and supplier pricing
• Potential annual savings based on usage

Driven by growing market interest, Fulton is reintroducing the FBS horizontal firetube steam boiler to meet increasing demand for high-output solutions in applications where space and headroom limit the use of vertical models such as the VSRT. Engineered for demanding process environments, the FBS range will be available in the UK with steam outputs up to six tonnes.

Commenting for Fulton, Sales & Marketing Manager Mat King says: “Fulton is reintroducing the popular FBS to the UK for customers who need high steam outputs but do not have the required height for their vertical boilers. The FBS is already renowned across global markets and in the UK and will deliver the performance expected from Fulton in an architecture that fits the space and keeps projects moving.”

Powerful steam performance

The FBS delivers robust steam outputs that suit sites with sustained, high-demand duty cycles, including manufacturing, food and beverage processing and large-scale laundry and dry-cleaning operations. Across the eight-model range, typical steam outputs are between 960 kg/h and 6,260 kg/h, giving end users the flexibility to match boiler selection precisely to the load profile. Fulton’s three-pass design provides efficient combustion, utilising corrugated furnaces that enhance efficiency and structural integrity by increasing heat transfer surface area and providing flexibility to absorb thermal expansion achieving long-term reductions in fuel use and operating costs.

Horizontal design for low headroom sites

As a horizontal firetube boiler, the FBS fits plant rooms where ceiling height limits the installation of vertical steam boilers and without compromising steam output or steam quality. Its generous water content and steam volume promote stable operation and high-quality, dry steam, which is essential for consistent process results and productive plant performance. The fully water-backed turnaround and carefully engineered pressure vessel design also help to minimise thermal stress and extend boiler life in tough operating environments.

“Plant operators want reliable steam, predictable operating costs and the confidence that their boiler choice supports their emissions strategy.” adds Mat. “The FBS gives them that confidence, combining a low NOx burner, high efficiency and Fulton’s proven firetube design to create a boiler that works brilliantly today and is ready for tomorrow’s demands.”

Ready for regulations and multiple fuels

Fulton equips the FBS with a low NOx burner package that enables the boiler to meet current emissions expectations, including MCPD requirements, when specified appropriately for the site. Burner options can fire on gas, oil or dual-fuel giving plant operators valuable flexibility where fuel availability, security of supply or resilience strategies demand a secondary option. In addition, the boiler’s high efficiency and modern burner technology support decarbonisation plans by helping operators cut both fuel consumption and associated emissions.

Durability and low total cost of ownership

The FBS features pressure vessel thicknesses that exceed relevant code minimums and tubes that are significantly thicker than many industry-standard designs, reinforcing its rugged, long-life construction. Fulton’s hinged front and rear doors make fire-side access straightforward, while seal-welded tubes and a fully water-backed rear turnaround reduce the risk of leaks and maintenance-related downtime.

Where design criteria demand even higher efficiencies, the FBS can be provided with a flue gas economiser, with every boiler supplied with brackets and supports to minimise the impact of having one retro fitted. In addition, high-density insulation reduces jacket heat loss, supporting overall system efficiency and helping to drive down total cost of ownership over the boiler’s lifetime.

Summarising, Mat King says: “From food and beverage to healthcare, textiles and manufacturing, engineers can specify FBS knowing that its horizontal layout, high steam outputs and fuel flexibility will help them design a practical, productive and future-focused boiler plant room.”

www.fulton.co.uk

When it comes to transfer applications, there’s no shortage of pumps to choose from. Often the challenge isn’t finding a pump that will do the job — it’s finding the right pump.

Our XCP ATEX End Suction Centrifugal Pumps

On paper, several options may look perfectly suitable. But real-world reliability often comes down to something that can’t be found on a datasheet: experience.

Recently, an oil refinery approached us after experiencing repeated failures with two progressing cavity pumps used for slop water transfer. The pumps were failing when brought back into service following extended periods of shutdown.

Located at a remote site, the pumps were particularly susceptible to seal damage and rotor seizure after prolonged periods of inactivity. The site's remote location made regular maintenance visits both costly and time-consuming, while the need to attend to pump failures often arose at short notice, creating additional operational challenges.

Existing Process Pump Problems

There are applications where a progressing cavity pump is an excellent choice — particularly when handling water with an uncontrolled oil emulsion, with varying viscosity, and solids content, for a process which demands a consistent flow rate.

On paper, the pump selection appeared to tick all the right boxes. The duty was understood, the operating conditions were considered, and the pump looked like the right fit. But, as we know, what works on paper doesn’t always in practice.

Irregular use was a major problem

Progressing cavity pumps are generally better suited to regular operation, as extended periods of inactivity can cause seal faces to stick and rotating components to bind or seize. To eliminate these recurring issues, our client wanted to replace the existing progressing cavity pumps with an alternative design that would be easier to maintain and better suited to intermittent or infrequent operation, without the risk of damage caused by prolonged periods of inactivity.

They also wanted to upgrade the existing produced water transfer pumps without making any changes to the site's electrical infrastructure. This placed two key requirements on the replacement pumps: the motor power had to be limited to 7.5 kW or less, while the pumps also needed to be available within a lead time of 13 weeks.

Technical Considerations

The process also demanded a number of design considerations both for ease of process connection and enhanced durability. These included ANSI Class 150 flanges, and a flushed Mechanical Seal Plan (plan 11) where fluid is recirculated from the pump discharge through a pipe into the seal chamber, acting as a flush to keep seal faces clean and cool.

As an independent pump specialist, North Ridge Pumps is not tied to a single pump technology, allowing us to select the most suitable solution for each application with lifetime cost in mind.

Our experience enables us to provide tailored pumping solutions based on the specific requirements of each process, rather than taking a one-size-fits-all approach. With over 100 real-world pumping applications we know how to get it right.

Our XCP end suction horizontal centrifugal pumps

XCP Pump with Seal Flushing Plan.

The process pumps chosen were our XCP end suction horizontal centrifugal pumps designed for clean or contaminated fluids with low viscosity. This is a robust process pump with additional bearings in the pump head in an oil bath designed for heavy duty 24/7 operation.

The pumps are designed for the transfer of low-viscosity, clean or slightly contaminated fluids. Manufactured to ATEX requirements, the units feature brass coupling guards, anti-static paint and dedicated earthing connections on the baseplates to ensure safe operation in potentially hazardous environments.

Following manufacture, the slop oil pumps underwent independent third-party BV Witness testing and inspection, including performance testing, hydrostatic pressure testing and material inspection to verify compliance with the required specifications.

If you have an application involving the transfer, circulation or injection of viscous solid-laden liquids and are unsure which pump to use, speak to North Ridge Pumps to see how we can help.