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Borger has launched a new cutting-basket macerator that helps protect wastewater/biogas pumps and downstream equipment by consistently mashing solids.

Designed with pivoted cutting blades that adjust automatically, the OrbitGrinder operates at an even cutting speed, with its cutting basket’s blades arranged in a special star shape to maximise shredding.

Not only is flow through the OrbitGrinder’s cutting basket homogenous, but the baffle plate also ensures that the suction force of the pump is evenly distributed.

Compared to standard, round perforated disks, the circumferential speed of the Orbitgrinder’s blades is the same in every cutting point, delivering uniform macerating results. Macerators with round perforated disks also typically see excessive wear of the cutting plates’ outer edge, whereas the OrbitGrinder’s design and durability provides a significantly prolonged service life.

The OrbitGrinder’s simple inlet and outlet can be positioned at different angles to suit, and with the top and bottom parts connected by standard screws, this highly effective new macerator can be easily integrated into any existing system.

As with all proven Borger equipment, the Maintenance-In-Place design makes servicing much easier than laborious alternatives. The OrbitGrinder benefits from a gas strut assisted quick-release cover. Impurities are sent into the debris collector.

Borger UK

01902 798 977

www.boerger.com

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For over 16 years, the composite wrap system, Belzona SuperWrap II, has been applied throughout multiple industries to restore the strength of holed, weakened and corroded assets. Now, the R&D Department at Belzona Limited has honed the capabilities of this technology so that, with the new epoxy resin, Belzona 1984, this technology is now optimised to be applied in aqueous environments.  

Figure 1. Application of composite wrap system in submerged environment  

Surface-Tolerant Composite Repair System Optimised for Underwater Maintenance

One of the key individuals behind the development of the new surface-tolerant composite repair system, Ian Wade, Technical Services Manager at Belzona Limited, explained more: “The Belzona SuperWrap II compliant system already features three resins designed for different application and service temperatures. Belzona 1984 is the latest development in this system, engineered specifically with surface tolerance in mind. This resin can be applied directly to damp, wet and underwater surfaces without the need for abrasive blasting.”

Figure 2. Ian Wade, Technical Services Manager at Belzona Limited

Ian continued: “Once cured, Belzona 1984 resists temperatures of up to 50°C (122°F) and can be applied in temperatures ranging from 5°C to 40°C (41°F to 104°F). The Belzona SuperWrap II system can be applied as a composite wrap, pad, plate or patch, depending on the application requirements.”

Figure 3. Application and service temperatures of Belzona SuperWrap II resins  

Full Compliance with ISO and ASME Standards

The Belzona 1984 system has undergone rigorous testing and is fully approved for compliance with ISO 24817 and ASME PCC-2 standards. These tests utilised samples which were applied and cured underwater in artificial seawater, representing the worst-case and most aggressive environments. Compliance with these standards demonstrates how Belzona SuperWrap II is optimised for use in a variety of challenging environments, making it a welcome addition to many a maintenance engineer’s repertoire of repair solutions.

Figure 4. Composite wrap system, Belzona SuperWrap II, incorporating Belzona 1984

Rigorous Training Programme Ensures Excellent Standard of Application

In order to apply Belzona SuperWrap II to ISO/ASME standards, applicators are required to complete a rigorous training programme at one of Belzona’s 16 training centres located worldwide. By thoroughly equipping applicators with the skills and expertise to successfully apply the composite wrap system, this ensures that an excellent standard of application is maintained.

To uphold this standard, every two years, Belzona’s Corporate Belzona SuperWrap II Trainer Committee conduct a mandatory audit of all Belzona SuperWrap II trainers, facilities as well as internal staff. Upon successful completion of the audit, Belzona SuperWrap II accreditations are then renewed. Again, this process is designed to ensure a consistently safe and successful application of the composite wrap system.  

Bypass Carbon- and Cost-Intensive Replacement Process

As industries continue to ratchet up their carbon mitigation measures in line with the net-zero by 2050 pathway, the use of polymeric repair and protection technology offers a real boon for maintenance engineers. The process of replacing damaged assets incurs a hefty carbon footprint, not to mention considerable financial expenditure. With polymeric technology, engineers can successfully bypass the carbon- and cost-intensive process of replacement, and instead rehabilitate their assets and protect them against future damage. Now, this can be achieved even in the most challenging application environments thanks to the surface-tolerant epoxy resin, Belzona 1984.

Figure 5. New surface-tolerant epoxy repair resin, Belzona 1984

How to run ladders, podiums and steps inspections?

Ladders, podiums and steps should be regarded primarily as a means of access. If used in the workplace this should only be for short periods of time and only then if the use of more suitable equipment is not justified because of low risk and/or when the residual risk is adequately controlled. It is generally safer to use work equipment such as tower scaffolds, podium steps, temporary stairs or MEWPs (Mobile Elevating Work Platforms) than ladders.

OSHA (Occupational Safety and Health Administration) requires employers to ensure that ladders, podiums, and steps are inspected regularly for defects and repair or replace any that are found to be damaged. Employers must also train employees on how to properly use, maintain, and inspect ladders, podiums, and steps to prevent accidents. If an employee is found to be using a ladder, podium, or step that is defective or damaged, the employer may be cited by OSHA for a violation.

Our recommended actions:

• Have a system of identifying when ‘unsafe’ or not to be used
• Be given a unique identification mark or tag
• Be recorded in a suitable register
• Have appropriate records of inspection, repairs or maintenance
• Be checked daily and prior to any use for damage, faults and wear
• Be inspected by a competent person at periods determined by type, intended use, work conditions, place of use, age and previous use
• Be stored in suitable areas and conditions

Reference to the Provision and Use of Work Equipment Regulations 1998, manufacturer or supplier information and the risk assessments for the work to be completed will give guidance relating to required competent person inspection checks and periods.

Laddertag from Scafftag

Laddertag is the original and industry leading status tagging system for ladders. A complete range of ladder inspection systems are available to control your ladder safety, inspections, maintenance and identification. Laddertag is a robust and highly visible system for displaying information relating to a ladder's class, inspection period and inspections due as well as a handy, quick-reference ladder inspection checklist. It is for this reason that it has been adopted by thousands of leading ISO 9000 companies.

Watch the short video how to use a laddertag >>

Scafftag – A Brady business

Units 22-28, Atlantic Business Park, Hayes Lane, Sully, CF64 5AB

Phone: +44 (0)845 089 4060

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www.scafftag.co.uk

Integrated Global Services, Inc. (IGS), a leading provider of proprietary asset integrity and environmental and efficiency technologies, is pleased to announce the acquisition of the engineered coatings and materials business of Liquidmetal Industrial Solutions. Based in Chattanooga, Tennessee, the coatings and materials business specializes in high-performance thermal spray application services and materials.

IGS leverages its physical presence across six continents to provide a global customer base with robust, purpose-built surface enhancement solutions across a diverse set of equipment and end markets.

This acquisition expands IGS's asset integrity technology portfolio, enhancing IGS's ability to offer customers the optimal thermal spray solution for their unique needs. Several North American personnel from Liquidmetal Industrial Solutions will be joining IGS.

"We are excited to welcome the experienced team from Liquidmetal into the IGS family," said Rich Crawford, President and CEO of IGS. "IGS's technology leadership, engineering excellence, and global operating platform – combined with Liquidmetal's innovative line of patented Armacor® and other material technologies – create compelling opportunities for continued global adoption of HVTS® across a wide range of industries."

"IGS is excited to support former Coatings and Materials Business customers," Hayden Hill, COO of IGS, added. "We will continue to offer the same technology they have relied upon in the past. These customers will benefit from greater operational and technical resources, as well as a broader suite of capabilities."

Liquidmetal Industrial Solutions will continue to offer a range of unrelated mechanical and inspection solutions after the divesture of its engineered coatings business to IGS.

Lifting Equipment Engineers Association (LEEA) Chair, Oliver Auston, welcomed guests to the LEEA Awards 2024 at the world famous Dorchester in London on the evening of 16^th October. He proclaimed the event, celebrating its 6^th year, to be the biggest yet with more people at the ceremony, a record number of high quality entries from LEEA members around the globe as well as more finalists. The winners of the awards are as follows:

• Emerging Talent Award: Bradley Seaman, IMES International Ltd
• CEO Award for Services to Learning and Development: Andy Dowd, Speedy Hire
• Trainer of the Year - The Craig Morelli Award: Ashley Hall, Kito Crosby
• Excellence in People Development: Jo Stamp, Sunbelt Rentals
• Technical Excellence and Professionalism Award: Anton van der Zalm, Van Beest
• Excellence in Leadership: Hadi Al Sagour, Saudi Aramco
• Sustainability Excellence Award: Bunzl Safety and Lifting
• Excellence in Service Innovation: Test & Inspection Department, Select Plant Hire
• Excellence in Product Innovation: RUD Twin Trigger ROV Hook, RUD Chains Ltd
• Excellence in Safety: Bunzl Safety and Lifting
• Excellence in Lifting Operations: Beryl Alpha Lifting Team, Apache Corporation

Guests were introduced to LEEA’s chosen charity, Demelza, which delivers extraordinary care to extraordinary children facing serious or life-limiting conditions, providing support for all the family. Special guest, former Special Forces Sergeant Jason Fox, then regaled the audience with stories stretching from his time in the forces to his recent experiences in the world of TV.

Thanking the Board for continuing to seek excellence, LEEA CEO Ross Moloney, who co-hosted the evening with Oliver Auston said: “Lifting is an outstanding and crucial part of the economy. It is about problem solving, making dreams come true and, at the end of a shift, that we go home safely. Congratulations to the eleven recipients of our trophies. You are designated representatives of excellence, built on pillars of innovation and safety. I thank all the nominees as well as the sponsors and judges for their essential contributions. See you at the LEEA Awards 2025.”

Winners in detail

Details about the LEEA Award winners 2024 are as follows:

Emerging Talent Award, sponsored by Bridger Howes Limited, celebrates individuals who show exceptional promise, initiative and potential for future success, serving as role models and inspirations to others.

The winner is Bradley Seaman, IMES International Ltd. Brad is an absolute credit to IMES and to the Lifting Industry as a whole. He has exactly the right attitude and drive that the industry needs right now and the company is very much looking forward to helping him develop into the new era of Lifting Equipment Technician and beyond.

The judges said: “Brad is the epitome of emerging talent” and “appears to be a very energetic and proactive person and is obviously keen to learn and develop his knowledge and skills.”

Runner up was Rory Stewart of Europa Engineering Group.

CEO Award for Services to Learning and Development. Ross Moloney, CEO of LEEA said: “Sometimes there are candidates for the awards who are worthy of special recognition outside of the category for which they applied. How we develop pathways for our new recruits and then how we support our students as they progress onwards in their career is one of the most important challenges faced by the industry.

The winner is Andy Dowd, Speedy Hire. Andy is the Lifting, Training and Development Manager at Speedy Hire. His commitment to education, mentorship and excellence has made a significant impact on the Speedy organisation. He has been a key figure in developing their lifting engineers, nurturing the next generation of talent and elevating training programmes.

Moloney added: “Andy Dowd is clearly an outstanding example and advocate of learning and development in the industry. In addition to completing four LEEA Diplomas himself, Andy is the Speedy main contact for the LEEA Accredited Training Scheme, which has ten approved courses. He is a member of the LEEA Learning and Development Committee and has been shortlisted three times for the trainer of the year. His determination to innovate in terms of teaching methods and mentor apprenticeships really stood out, and I believe it is wholly fitting that we recognise his service to the sector both in and out of the classroom.”

Trainer of the Year - The Craig Morelli Award recognises and celebrates trainers from the LEEA Accredited Training Scheme who excel in their profession and make significant contributions to the development and success of others.

The winner is Ashley Hall, Kito Crosby. Ashley has worked within the Lifting Industry for 31 years, 16 with Crosby, and has been training for over 10 years. He is a member of the LEEA Technical Committee, an Accredited Training member and has been a board member for four years. He is also a member of the Crane Forum in Aberdeen and the ILLAPG (Industry Lifting Lead AP Group).

Deeply passionate about safety and committed to ensuring that everyone understands the importance of proper training, Ashley’s dedication inspires both customers and colleagues. Recognised as a subject matter expert within the industry, he combines extensive training and practical experience, approaching his role with the utmost seriousness.

Ashley is the main custodian of the Kito Crosby Rig Safe, Rig Crosby trailer, promoting safety within the Lifting Industry. The trailer is a key element in the company’s training programme and Ashley travels throughout the UK and Europe for seminars, open days and training sessions.

The judges said: “Having witnessed Ashley at work I believe he is an excellent candidate for the award.” Also: “The onsite trailer and Ashley’s delivery is a major progressive step in training and the overall result is one of consistency and excellence.”

Runner up was Russell Reid of Boilermakers Lodge 146.

Excellence in People Development celebrates people and organisations that prioritise the growth and development of their people, particularly where they foster a culture of learning, innovation and excellence.

The winner is Jo Stamp, Sunbelt Rentals. With a 35 year career in the hire industry, including 9 years with Sunbelt Rentals, Jo showcases dedication to encouraging development and growth of people within the organisation and the wider industry.

Jo has demonstrated her commitment to mentorship and personal development by mentoring numerous employees, guiding them towards professional success and personal development. This dedication was recognised at the 2024 CPA (Construction Plant-hire Association) awards, where Jo received the ‘Highly Commended’ Award for her outstanding mentorship.

Jo’s influence extends beyond formal mentorship. She is known for her personal support to colleagues, always available to offer her expert advice, discuss projects, address issues or assist with customer enquiries, regardless of the time of day. Her open door policy and approachable nature have made her a trusted teammate and advisor within the industry.

The judges said: “Jo has developed a real skill for people progression,” and is “an experienced, talented and knowledgeable people-manager… it is very clear that Jo is highly thought of in Sunbelt.”

Runner up was William Hackett Ltd

Technical Excellence and Professionalism Award recognises individuals who not only excel in their technical abilities but also demonstrate professionalism, leadership and a commitment to continuous improvement in their field.

The winner is Anton van der Zalm, Van Beest. Anton is a technician from the heart. With his background as a teacher in physics and chemistry, sharing technical knowledge is what he loves most. Working with Van Beest for 20 years, he is now VP Corporate Research & Development with responsibility for all technical challenges, choices and developments. Within the company, this is the highest technical position and part of the ‘Leadership Team’. Safety procedures, testing and quality control are his highest priorities.

The judges said: “Anton has made a great contribution to Royal Van Beest and the Lifting Industry over many years. He deserves this award.” And: “Anton is shown to be very professional and his technical abilities are well known, a very impressive nominee.”

Runner up was Jim McDonald, IMES International Ltd.

Excellence in Leadership, sponsored by Hoist Magazine recognises an individual who has proven to be effective in improving or growing their firm. It seeks evidence of vision, ambition, dynamism and marrying the sometimes competing factors of strategy and day to day operations.

The winner is Hadi Al Sagour, Saudi Aramco. Hadi Al Sagour is the Manager of the Engineering and Technical Support Division within Aramco Mobility and Logistics Services Department. In this role he has made significant contributions that greatly improved Aramco crane and lifting services activities. He has had a noticeably positive influence on the Lifting Industry, building on both his strong technical background and management role within his company. His excellent leadership skills encourage his team to follow him.

Hadi’s journey in the Oil and Gas Industry has been nothing short of remarkable. From humble beginnings to a distinguished leader, his contribution has not only propelled the organisation forward but has also set new benchmarks for industry standards. His innovative approach, coupled with rich experience and unique influence has earned him a reputation as a visionary leader.

The judges said: “Hadi is highly accomplished and his successes far surpass other applicants. Not only is he a leader in business but Hadi is a leader in the Lifting Industry and the Middle East’s safety developments in various industry sectors.” He is “making a great  contribution to the success of Aramco.” And: “A clear industry leader in a large organisation.”

Runner up was Simon Luke of Reid Lifting.

Sustainability Excellence Award looks for evidence of successfully wrestling with any type of sustainability related challenge, be it related to workforce, energy use or supply chains. The shortlisted candidates have all demonstrated success in improving business practices to improve their longevity and lower their impacts.

The winner is Bunzl Safety and Lifting. Bunzl’s sustainability strategy was created following in-depth research and wide consultation with key stakeholders. This produced a four pillared approach: supply chain, people and community, products and customers, and environment and climate change. Eight key targets ensure progress in delivering the aspirations of the company, which include phasing out single use plastics, creation of an equitable and inclusive working environment, establishing a compliant network of suppliers and at least half of operational waste being recycled.

The entry showed clear evidence of action as well as aspiration, with case studies showing improvements in how the company is eliminating plastic waste, switching to renewable materials and reducing pallet wrapping.  Where there may be uncertainty about the balance between the costs and benefits of sustainability, Bunzl showed how a commercial business can be focussed on sustainability.

The judges said: “Bunzl is the outstanding nominee in this category.” It’s “sustainability programme is well detailed.” The entry was “a very thorough and professional display of a modern company making a positive difference to the world they trade in”.

Runner up was Speedy Hire.

Excellence in Service Innovation seeks to celebrate services that have improved in an innovative way. It looks for creativity, originality and either improvement or creation of brand new services that give added value to the customer.

The winner is Test & Inspection Department, Select Plant Hire. Select Plant Hire has invested significantly in its T&I department to ensure clients, both internal and external, are provided with the best possible services, solutions, innovations and the highest standard of independent inspections. The natural growth and development of the department means more T&I services have been brought back in-house (tower and crawler cranes) while ensuring they are always operating with the current legislation and industry guidance.

The judges said: “Bringing the service back in-house is commendable. A high standard is set and to some degree higher than required.” It is “a well thought out and comprehensive service package that benefits everyone in the chain.”

Runner up was RiConnect Rental Module, RiConnect UK Limited.

Excellence in Product Innovation, sponsored by International Lift and Hoist, seeks to highlight the new and creative products that are entering the marketplace from our members. Shortlisted candidates have all created products that take the lifting world forward. Their innovative products mean that the world can go higher, further and safer in tougher environments.

The winner is RUD Twin Trigger ROV Hook, RUD Chains Ltd. Historical data shows frequent offshore incidents involve a hook snagging on rigging and the unintentional release of the load, known as shedding. The RUD Twin Trigger ROV Hook has been engineered to surpass the industry’s stringent safety and efficiency standards, reducing operational downtime and associated costs. This hook boasts a unique outward opening safety mechanism with just two moving parts, enhancing both safety and ease of use.

The judges said: “The RUD ROV Hook has been designed to set itself aside from other products on the market for subsea application and focuses on safety and ease of use to streamline subsea tasks. This product is deployable across the global market and could be developed to solve similar issues in other sectors”.

Runner up was VisionTek, Bridon International Ltd.

Excellence in Safety, sponsored by Rigging Services applauds the organisations that prioritise the health and safety of their employees and demonstrate leadership, innovation and continuous improvement in safety management. 

The winner is Bunzl Safety and Lifting. Bunzl’s corporate wide commitment to safety was hugely impressive. Irrespective of position or seniority, all of its staff and customers benefit from numerous initiatives designed to deliver safety. These include an Incident and Reporting App, a culture where all staff are involved in reporting incidents, intra-team Bunzl games used internally to drive through the safety culture and clear reporting by branch. Bunzl provided numerous examples of the steps it has taken to ensure safety within its workforce, both in terms of investment in infrastructure and equipment and in recent changes to how pre-set checks on machinery help to manage risk. Work to support field inspectors was also extremely impressive.

The judges said: “I like the idea of using a positive message to achieve progress over something that is negatively perceived, such as inter-branch competition.” And: “The B safe inspections are very good and ensure that all people have to make the correct safety checks before using the equipment.”

Runner up was Lifting Department, Select Plant Hire.

Excellence in Lifting Operations, sponsored by IMES, recognises and celebrates individuals or teams that excel in conducting lifting operations safely, efficiently and in compliance with regulations and best practices.

The winner is Beryl Alpha Lifting Team, Apache Corporation. In 2023, a motor within a gas compressor on the Beryl Alpha failed, limiting natural gas export from the platform in the North Sea. Located in an extremely cramped and enclosed space, the repair could not be conducted safely in location and the motor had to be removed and shipped onshore, an extremely complex process never attempted in the platform’s 47-year history.

What ensued was a remarkable feat of lifting mastery in just 37 days. With only 50 mm clearance either side of the motor for removal, high ambient temperatures and working at height in proximity of a live plant containing hydrocarbons, full proof planning and flawless execution was essential. With intricate planning and outstanding teamwork, no accidents or incidents were recorded for the removal and reinstallation. An incredible team accomplishment.

The judges said: “A classic well thought through lifting operation. I liked the use of multiple methods, such as jacking, skidding, lifting and pulling.” And it was “a well planned and executed lifting operation with safety at the forefront.”

Runner up was UniShore Lifting Truss, MGF Trench.

For more information, visit leeaint.com and awards.leeaint.com

The transformation in companies, which is made possible by the potential of artificial intelligence, represents one of the key challenges and opportunities of the future. The key technology of AI offers considerable potential for value creation, which is reinforced by the rapid advances in the field of large language models (LLMs). These developments are leading to a fundamental disruption of previous approaches in the AI sector.

Generative LLMs such as ChatGPT, Bard or LLaMA use advanced deep learning techniques and huge data sets to recognise, interpret and generate human language and complex data. The impressive results in text generation and other creative areas are not only milestones for the optimisation and digitalisation of existing processes, but also make a decisive contribution to the transformation of new areas of application by automating them and thus fundamentally changing the way we work and communicate.

Many companies are currently still in an experimental or pilot phase, trialling the latest AI applications in various business areas to test their efficiency and effectiveness. Nevertheless, their transformative power will bring about profound changes in the way companies work and communicate in the long term.

Five examples of current and future AI use cases

Below are some examples of how AI can be used in various industries and business areas today and in the future to optimise operational processes and enable new business models. These examples range from general applications to specific niche applications that demonstrate the versatility and potential of AI.

1. Analysing and evaluating large amounts of data

The use of AI for analysing and processing large volumes of data opens up a wide range of possibilities and applications that go far beyond the limits of traditional methods: For example, it can help to better design individual services and products. For example, the AI sub-area of natural language processing (NLP) can already be used in the insurance industry to analyse patterns and trends in data and compare documents at content level. Changes to general insurance conditions can be recognised in this way or an insurer’s services can be compared with the current market offer. Due to their complexity, these tasks are particularly time-consuming and error-prone when performed manually. With machine support, complex documents can now be automated, analysed and compared at a semantic level, significantly reducing errors and effort.

2. Customer communication in specific industries

One example of a specific niche application is the use of AI in customer communication. The use of large language models in particular offers an improvement in customer interaction through natural language dialogue systems. In sectors such as banking, insurance or telecommunications, this can help to process customer enquiries more efficiently in future through a high degree of automation and offer hyper-personalised advice and customer contact. Well-trained LLMs can respond even more individually to customer needs, suggest suitable products or services and feed findings back to the company in order to collate this customer information in compliance with data protection regulations.

3. Enterprise asset management and predictive maintenance

A special use of AI can be found in the area of enterprise asset management. AI is already being used in industry today to predict and carry out maintenance before faults occur. This predictive maintenance is based on the analysis of sensor data and other relevant information in order to recognise patterns that indicate possible equipment failures. In this way, specialists are informed before a fault occurs that a particular component is worn and should be replaced. Intelligent image processing systems are another field of application for AI in industry. These support quality control by automatically recognising errors in certain manufacturing processes.

4. Software development

In the field of software development the use of AI will help to speed up development and make it more efficient in the future. Application scenarios include the automation of routine tasks, the generation of standard code or the use of large language models (LLMs) as intelligent tools for answering technically demanding questions.

Current challenges and limits of AI

Investing in innovative AI-based systems can give companies a significant competitive advantage by using data-driven insights and automation to optimise processes or open up entirely new areas of business. However, these advances also bring with them ethical and data protection challenges as well as security risks that need to be addressed appropriately in each use case.

AI applications are only ever as good as the quality of the models and training data they use. Large language models in particular are currently dependent on a huge amount of high-quality training data, which could soon run out. At the same time, these new generative AI applications still raise unresolved questions regarding data protection and privacy rights as well as compliance with the General Data Protection Regulation (GDPR), which are currently being examined by the European data protection supervisory authorities.

AI hallucinations are also a known problem of generative language models, where the chatbot provides incoherent or incorrect answers. Risks also lie in possible distortions with regard to criteria such as origin, gender or other characteristics that can be reproduced based on historical data and the prejudices contained therein.

In the field of software development, there are currently concerns about AI-generated software being used incorrectly without human supervision and expertise. This is because poorly written code by AI systems could cause more damage than help solve problems in the future due to the resulting potential security vulnerabilities.

Human expertise remains essential

The current challenges and technical limitations make it clear that artificial intelligence is a valuable tool to support specialists in companies in their work. However, in critical or sensitive use cases, such as the evaluation of promotions, accounting and controlling processes or claims settlement in the insurance sector, which have a significant impact on customers, decisions should not be left exclusively to AI. For business-critical decisions, human expertise and experience remain essential to safely and effectively utilise the current capabilities of AI. This connection between human and machine is crucial for business transformation as it increases efficiency while ensuring the quality of decisions.

Author Martin Hinz, CEO and co-founder of Convista, has been with the Convista Group for over eleven years. Since 2012, Hinz has been a member of the Management Board of ConVista Consulting AG. He has more than 20 years of experience in software development in the insurance business. He is available for interviews as an expert concerning digitalization as well as it - and business transformation related topics.

Producing several million sustainable beverage cans per hour across its European plants, a can manufacturer needed to avoid unplanned machine downtime; the company was looking for a condition monitoring solution that was easy to operate and provided a simple way for the maintenance team to keep a close eye on all the machines.

Schaeffler’s certified service partner Faber Industrietechnik recommended their OPTIME Condition Monitoring (CM) solution. More than 5,000 sensors now monitor process-critical machines in all the customer’s European plants. In approximately two years, OPTIME CM has detected more than 500 critical faults and has provided numerous early warnings. In this time, a total of 180 unplanned downtimes (360 hours) have been avoided.

Challenge

The customer produces several million beverage cans a day at one of its plants in Germany. Depending on requirements, up to 20 process steps may be required to manufacture the beverage cans from aluminium coils. Process-critical machines such as the deep-drawing (cupping) machine, body maker, printing machine and auxiliary units such as motors, fans and pumps are heavily stressed in the process. The machines operate in shifts around the clock seven days a week.

It is not possible for impending damage on machines to be “heard” because it is a “loud” process. In addition, the machines are sometimes difficult to reach. For safety reasons, some machines are protected behind a protective guard or grid. Keeping an eye on numerous drives also poses new challenges every day for the maintenance team.

In order not to jeopardise the operational processes and to avoid unplanned downtime, the company relied on regular manual measurements, which were performed by Faber Industrietechnik until 2020. If a machine fails unexpectedly, part of the production facility has to be stopped. This incurs extremely high costs in terms of personnel, material and scrap. Manual measurements are no longer sufficient for reliable planning. The customer needed a European-based solution that could be expanded to all world-wide locations for can and lid manufacturing.

Solution

What started as 50 OPTIME CM sensors installed in the first plant has turned into more than 5,000 sensors installed across several European plants by September 2023. Initially, only a few machines were monitored using OPTIME CM. After the initial successes, the solution was expanded to other European plants. In addition, lubrication monitoring using the Schaeffler OPTIME C1 is also used in some of the customer’s plants. 

Case 1 – Plant in southern Germany: 24 hours of unplanned downtime avoided

In a plant in Germany, auxiliary units such as main drives, pumps, gearboxes and fans on critical machines have been monitored with OPTIME CM since May 2021. Around six months after installation, several faults were displayed on the dashboard. Among these were, for example, bearing damage on the main drive motor of the exhaust air treatment unit, pump defects in the wet system, and various faults on other machines. 

Damage detected on an exhaust air motor

Shortly after the OPTIME sensors were installed, motor damage was detected. The maintenance team confirmed this. When the motor was inspected during a planned replacement, the bearing was found to be damaged due to passage of electrical current. Without OPTIME CM, the defect would not have been detected until much later. High consequential costs were therefore avoided.

Case 2 – Plant in eastern Germany: 31 hours of unplanned downtime avoided

In another plant in Germany, critical auxiliary units such as motors, gearboxes, fans, pumps and drives, as well as air extraction, air supply and air recirculation fans on all machines (i.e. the pin oven, decorator, body maker, and more) have been monitored with OPTIME CM since February 2022. From February 2023, the OPTIME C1 lubricator has been used primarily to supply pin ovens and exhaust fans with the necessary amount of grease.

Numerous faults have been detected at an early stage and several cases of unplanned downtime have been avoided. Here is an example:

Alarm on decorator 2

Two weeks before the main alarm limit was exceeded in April 2023, a slight rise in the ISO value on the guide roller on the decorator was seen on the dashboard display. The maintenance team confirmed that a defective bearing was the cause of this. The bearing was replaced as planned. This saved 7 hours and cost savings were in the 5-digit range. After the bearing was replaced, the machine ran as normal without further problems.

Successful project

Thanks to the close cooperation between Faber and Schaeffler, the can manufacturer was completely satisfied with the CM solution. Through Faber, OPTIME CM was made available to all countries and provided installation support in Germany, with Schaeffler supporting across Europe with the installation. Plans to extend the monitoring solution are underway.

In Northern Lincolnshire, a Chopper Pump made by Landia has completed five years of continuous service at the main, 2MW biogas plant run by Singleton Birch, who for over two hundred years, have produced high quality lime products.

Working underground as part of an automated system for dirty run-off water, the Landia pump chops up maize and other particles that end up in the drainage; sending the recirculated liquid to the site’s lagoon, or back to the digesters as and when required.

“The Landia Chopper Pump does an excellent job,” said Danny Mason, Renewable Energy Supervisor at Singleton Birch, where the AD plant’s three 2800m³ digesters use a feedstock of maize, chicken litter and sugar beet.

He added: “The pump is very easy to maintain and has really helped us out with drainage on site, chopping up solids that would block up lesser quality pumps. Landia take care of the full servicing, and always ensure that there isn’t any downtime.”

Invented by Landia in 1950, the Chopper Pump is designed with an external knife system that continuously reduces solids.

In addition to this Landia unit at Singleton Birch, Landia has numerous Chopper Pumps installed at biogas plants as part of its digester mixing system. These include Scottish Water, Eco Verde Energy, and Republic Services in California.

www.landiaworld.com

If we look at the vibration time waveform from a damaged bearing, as detected by a vibration sensor (accelerometer) for instance, it will typically look like that shown below.

Picture this: A critical piece of equipment suddenly breaks down. You need a specific part to get it running again - but nobody knows where it is, or if it's even available. Downtime costs pile up, production grinds to a halt and stress levels rise. Sound familiar?

The challenge of spare parts management

This scenario is all too familiar to maintenance professionals. Managing spare parts is a challenging task - the balance between overstocking and running out is delicate. Effective spares management is key to minimising downtime, controlling costs and keeping production running smoothly. But traditional methods often fail to give you real-time information, visibility and control. That's where maintenance software like MaintMaster comes in.

How MaintMaster can transform spare parts management

Dedicated maintenance management software, such as MaintMaster, transforms the way you manage spare parts. With everything in one system, your team always knows where the parts are, how many are available and when they need to be reordered. No more manual tracking or sifting through paperwork. MaintMaster's powerful search functionality makes it easy to find parts, and its integration with procurement ensures that the parts you need are always available when you need them.

What sets MaintMaster apart is its ability to integrate and its flexibility to adapt to different processes. It connects seamlessly with other business systems, ensuring that all information - from suppliers to finance - flows smoothly. Need to track parts across multiple warehouses or sites? MaintMaster has you covered. Want to automate re-ordering to avoid stock-outs? It's all possible, tailored to your unique maintenance workflow.

MaintMaster also provides detailed analytics to help you understand usage patterns, optimise inventory levels and make data-driven decisions. With better visibility of your spares, you can reduce excess inventory, save costs and ensure the right parts are available when needed. This level of control helps to extend equipment life and improve overall operational efficiency.

MaintMaster's flexibility means it can adapt to the specific needs of different industries, from manufacturing to facilities management. It's designed to support the way your team works, with custom fields, workflows and reports that can be tailored to your exact requirements. This means you don't just get a software solution - you get a system that grows and evolves with your business.

Take the first step to smarter spare parts management

Improving your spare parts management doesn't have to be overwhelming. By implementing a system like MaintMaster, you can gain better visibility, reduce downtime and make your maintenance processes more efficient. Take the first step towards smarter spare parts management - start by assessing your current processes and exploring how a tool like MaintMaster can help address your challenges.

Contact:

MaintMaster Systems Ltd

Plexal, 14 East Bay Lane

Here East, Queen Elizabeth Olympic Park,

E15 2GW London, United Kingdom

Phone: +44 749 332 8466   E-Mail: This email address is being protected from spambots. You need JavaScript enabled to view it.