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MachineSafe is helping machinery end-users & consultants make time savings of up to 60%.

Since the successful launch, feedback from users has been very positive with regards to the ease of use of the MachineSafe platform and time savings when compared to their previous methods of carrying out compliance inspections.

MachineSafe is a multi-platform compliance tool to streamline machinery inspections. Inspection modules including PUWER, New Machinery Audits, LOP, Risk Assessment, EN 60204. In addition, users can add their own inspection templates. Multi-user is included as standard.

Please contact MachineSafe to arrange a demonstration.

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machinesafe.co.uk

01793 547018

Today, a staggering 34% of global greenhouse gas emissions come from food production. Whilst a large proportion of these emissions come from land use and agricultural production, the manufacturing stage alone emits over 2.4 billion tCO2e (Crippa et al). As large players in the food and drink manufacturing industry make plans for reducing emissions, it is vital to consider every way in which this can be done.

Furthermore, the Food and Agricultural Organisation (FAO) estimates food production must grow by 60% by 2050 to keep up with the growing world population. With this anticipated growth in the industry, it is even more important to shift the way we manufacture food in order to meet net zero.

How Can Manufacturers Increase Energy Efficiency?

To reduce emissions in food manufacturing, increasing energy efficiency is key.

Upgrading motors is an excellent long-term strategy for saving energy. In regions such as Europe and China, an electric motor’s efficiency is described by its International Efficiency Class (IEC). Food & Drink International (FDI) recently noted that increasing your motor by just one class will decrease energy losses by 20%. To encourage this, IE4 is now the minimum standard in Europe for new installations. Manufacturers should consider upgrading to the most efficient motor possible to lower their energy losses. For example, upgrading from an IE3 to IE5 can help manufacturers reduce their energy losses by 40%, significantly lowering their CO2 emissions.

A recent report for the Department of Climate Change highlighted the benefits of using variable speed drives (VSDs) in the food industry. Traditionally, mechanical control methods like throttles or brakes have been used to manage the speed of fans, pumps, compressors and conveyor belts. Switching to VSDs grants direct control of the motor speed and torque, which also reduces wear and tear on the motor and its machinery, increasing its longevity. This can significantly minimise energy loss - slowing down a motor by 20% can half the amount of electricity used. In fact, VSDs often recoup their cost through energy savings in less than a year, making them a straightforward and cost-effective means of boosting energy efficiency.

Decarbonisation of Heat Processes

To decarbonise the heat process manufacturers must switch from fossil fuels to renewable energy for heating.

Currently, gas boilers still dominate the generation of hot water, steam and hot air within the food industry. Presently, the upfront costs and low fossil fuel prices are the main barriers preventing manufacturers from implementing this change.

However, as we race towards achieving net zero emissions, an increasing number of manufacturers are realising food industry decarbonisation through the electrification of heat is crucial. Globally, as more countries continue to decarbonise their electricity grid, taking this step will continue to become more accessible and cost-effective.

Making the Switch to Sustainable Refrigerants

Whilst the emissions produced by the cold chain exacerbate climate change, the heating effects of climate change necessitate more cold storage. To break this cycle, we must make the cold chain more sustainable.

The cold chain is often overlooked when considering greenhouse gas emitters in the food industry, but it accounts for 4% of Global Greenhouse Gas emissions – equal to that of the entire continent of Africa. Furthermore, recent reports show the UK will require an additional 785,030 m² (8.45 million ft²) of cold storage by 2025. Therefore, the need for a more efficient and sustainable cold chain is more pressing than ever.

The UN notes that one important way to make the cold chain more sustainable is by reducing non-CO2 emissions from refrigerants. Hydrofluorocarbons (HFCs) used to be the norm in the industry, until it was discovered they are an extremely potent greenhouse gas. HFC-134a, the most common sort, has a global warming potential 3400 times that of carbon dioxide. Despite 152 states, including the EU, having ratified the Kigali agreement (a pledge to massively reduce the production and use of HFCs), there is still a lot of work to be done.

As shown in the figure below, 33% of cold stores built in the last five years are still using HFCs. More positively, CO2 is gaining popularity as it is a natural refrigerant and a great green alternative. Unlike traditional synthetic refrigerants, it has a significantly lower global warming potential. Ensuring manufacturers halt the use of HFCs in refrigeration systems and choose a more sustainable option is key to making the cold chain more sustainable.

Image source: Cold Chain Federation’s 2023 Cold Chain Report

Extend Lifespan of Food and Drink Assets Using Industrial Coatings and Composites

Among these tactics, protective coatings and epoxy repair composites have a key role to perform in the decarbonisation of the food and drink industry. Opting to use coatings and composites extends the working life of machinery, equipment and structures.

Companies like Belzona offer a wide range of coatings and composites. Many of them meet national and international standards for food contact and drinking water such as approval from the National Sanitation Foundation (NSF), Water Regulation Advisory Scheme (WRAS), and Food & Drug Administration (FDA). This makes them particularly well-suited for the food and beverage industry.

In this industry, food waste is a huge contributor to greenhouse gas emissions. Belzona’s fast application process minimises downtime, reducing product loss and keeping waste to a minimum. By focusing on repair and protection, Belzona helps food manufacturers operate more sustainably while also extending the lifespan of equipment.

Case Study: Corrosion Protection for Drinking Water Tank

This drinking water tank repair at a Food Manufacturer in Poland exemplifies Belzona’s rapid and sustainable repairs. The deterioration of the concrete within the tank was leading to poorer water quality, necessitating an urgent fix. Traditional methods, like using more concrete, would have led to a lengthy shutdown, increasing waste and incurring high costs. Moreover, this wouldn't prevent the issue from recurring. Instead, the Customer chose to use Belzona to repair and coat the tank, providing them with a long-term solution, and a quick application time.

First, the corroded walls needed to be rebuilt before a protective coating could be applied. After conditioning with Belzona 4911 (Magma TX Conditioner), the damaged areas of the substrate were rebuilt using Belzona 4111 (Magma-Quartz). Once the concrete was rebuilt, a coating needed to be applied to protect the walls of the water tank from further corrosion.

 Tank after rebuilding with Belzona 4111 (Magma-Quartz)

The chosen coating was Belzona 5811DW2 (DW Immersion Grade), a 2-part epoxy coating which provides outstanding chemical resistance and is ideal for use in the food and drink industry as it is solvent-free and has WRAS approval for contact with potable water.

First, the entire contents of the base and solidifier containers were mixed thoroughly until a uniform colour was achieved. The first coat of Belzona 5811DW2 (DW Immersion Grade), could then be spray applied to the tank. Later that day, a second coat was applied in the same manner, completing the two-coat system and ensuring maximum corrosion protection. This repair significantly extended the lifespan of this piece of equipment, showcasing Belzona’s sustainable solutions within the food and drink industry.

Drinking water tank repaired and protected with Belzona

Reducing the Carbon Footprint of the Food Manufacturing Industry

Ultimately, to achieve net-zero emissions in global food manufacturing by 2050, a multifaceted approach considering every possible strategy is key. Improving energy efficiency, switching to more sustainable energy sources and adjusting energy-intensive processes like heating and cooling to make them as sustainable as possible are just a few examples. Extending machinery and equipment lifespan via repair and protection systems, such as those offered by Belzona, is a key strategy for food manufacturers who are working towards reducing their environmental footprint.

Want to learn more about Belzona’s solutions for the Food and Drink Industry?

Click Here to Learn More

 www.belzona.com

The Enerpac the RC-Trio hydraulic cylinders range feature a new bearing system for enhanced durability and a hybrid spring-return system for up to 3x faster retraction. The general purpose RC-Trio range is the next 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 US’s no.1 expo will be back next June and is already 50% sold out – have you had a look at the Downstream USA 2024 Expo (June 26-27, Galveston) price list and booth availability yet?  

Next June 3,500+ petrochemical, refining, chemical and LNG decision makers and budget gate keepers will descend on Galveston for the 13^th year running to explore 160+ booths showcasing the latest in technology, equipment, components, and solutions to meet all their procurement needs and deadlines in 2024 and beyond!   
                                         

Click the link below for more infomation

Last year 74% of attendees stated they attended to learn from solution providers and 76% attended for networking! If you are looking to meet and network with major downstream producers and EPCs (50% attendee ratio), no other event attracts larger groups! Just look at our group sizes from 2023 -

• Dow 65+ 
• CP Chem 55+ 
• LyondellBasell 55+  
• BASF 50+  
• Shell 40+  
• Chevron 35+  
• ExxonMobil 25+ 
• Marathon 25+  
• Aramco 25+  
• INEOS 25+ 
• Ascend Materials 25+ 

                                   
Let us know if you have any questions! Contact our commercial team on This email address is being protected from spambots. You need JavaScript enabled to view it. to organise a call!

Established 60 years ago, Prosaw are one of the largest suppliers of Metal Sawing Machinery in the UK. Their customers range from Aerospace, Construction & Precision Engineering through to General Fabrication along with Oil & Gas companies. Part of Prosaw’s success over the past six decades has been its unrivalled After Sales Service. With a team of 9 dedicated engineers, Prosaw can install new equipment and carryout routine maintenance for customers throughout the UK and Europe.

Chris Burns Techical Director 

Robert O’Brien, Sales Director explains how some of this success has come about: “Organising a team of engineers take time and needs a certain amount of flexibility, especially when some customers desire an immediate response to their call out. Since Prosaw began using T Cards in 2015, the Service Department have been able give engineers real time work schedules that they can interact with themselves. This also allows the scheduling of work at Prosaw’s Kettering Workshop assigning the pre-delivery inspection of equipment. It has been a valuable tool that makes the work of organising engineers a lot easier.

T Cards Online is designed to be used like the tried and tested manual boards with all the tangible, visual benefits but with all the accessibility, features and analysis tools available digitally. Prosaw were quick to see the benefits this can provide both for planning and customer response times for their engineers. Chris Burns, Technical Director, commented; “I have used the system for nearly 10 years and been really happy with how simple and easy it is to adapt to our changing needs. Having the support team at T Cards has been a great help over the years when small chang

www.tcardsonline.co.uk

T Cards also have their 60th anniversary this year. Most will be familiar with the tried and tested physical T Boards. A lost cost solution of having a “Go to Board” is an essential tool. Simple to customize to your requirements, manual T Cards can actively help improve the efficiency of your operation, and now there is an even simpler way to digitalize your process.

An example of a successful business in a competitive market, Prosaw has shown how important it is to give the right tools to help staff with their daily tasks. Systems like T Cards Online can make a big difference in making efficiency and productivity savings by simply co-ordinating tasks and communicating updates in a clear simple way.

Having been in development for 10 years when Prowsaw first started looking for a solution, the foundations of the web based system were already in place. Most of the features and functionality had been developed via “customer lead” consultation and feedback. Having been specialists in planning for 60 years, T Cards Direct were able to lean on their vast experience and knowledge of visual planning systems. One of the prime requisites from those consultations was to have an intuitive and flexible system that clients can easily bespoke to their needs without exhaustive and costly software changes. For more information please contact us by telephone on 01732 871 417, visit our website tcardsonline.com or email us at This email address is being protected from spambots. You need JavaScript enabled to view it.

 The most straightforward approach is often the most effective, and for many organizations, having a well-structured visual plan is essential.

Enter T Cards, a tried-and-tested method for planning and control. Now, the as a web-based system, T Cards Online serves as the perfect management tool for tracking, allocating, and improving efficiency. It’s easy setup and user-friendly interface provides clear and precise “information at a glance”.

www.tcardsonline.com

Production Health and EAM pioneers team up to spark a new era of manufacturing innovation

Itasca, IL, and New York, NY, November 15, 2023 – Augury, a leading provider of industrial AI solutions that improve machine health and process health, and IFS Ultimo, a pioneer in cloud-based enterprise asset management (EAM) solutions, today announced a new partnership that vastly improves the connection between machine health and asset management. The collaboration addresses the critical issue of disconnected workflows between machines and the people who manage and maintain them through a dynamic, real-time asset management process.

Faster Reactions, Better Decisions

Augury’s machine health technology enables companies to monitor and optimize rotating assets, eliminate costly downtime, and use prescriptive and predictive insights to make informed maintenance decisions. Yet, to achieve superior operational efficiency, industrial leaders must combine machine data with EAM processes. To streamline this integration, Augury and IFS Ultimo will help organizations take control of their assets, increase uptime, manage costs, and foster a safe, healthy, and sustainable work environment.

The Augury and IFS Ultimo integration will allow AI-based alerts and notifications from Augury's Machine Health platform to seamlessly flow into IFS Ultimo for maintenance scheduling and planning. This eliminates manual guesswork and empowers maintenance teams to respond proactively to machine needs, reducing wasted efforts and costs. The collaboration unlocks a wealth of information that goes beyond machine health insights, offering new ways to assess risk, manage inventories, and optimize maintenance schedules.

"Our collaboration with Augury marks a significant step toward a new era of asset management,” said Patrick Beekman, Partner Solution Manager at IFS Ultimo. “By integrating an easy-to-implement and extremely scalable machine health insights tool within our EAM platform, we empower organizations to make data-driven decisions, reduce downtime, and enhance overall efficiency."

For current Augury and IFS Ultimo customers, the integration promises a transformative journey toward a dynamic, proactive organization that drives higher uptime, productivity, and cost management. For those not yet using these solutions, embracing the Augury and IFS Ultimo collaboration will ensure that maintenance teams become more efficient and capable, allowing the entire business to thrive.

Building the Connected Manufacturing Future

In the face of ongoing challenges such as worker shortages, generational shifts, and supply chain disruptions, manufacturing companies are intensifying their efforts to empower a new generation of connected workers. These workers are poised to lead the industry into the future of manufacturing, and the partnership between IFS Ultimo and Augury will help them, and their companies meet these ambitious goals.

"The manufacturing landscape is evolving rapidly, and it demands a shift from manual, reactive approaches to one that embraces real-time data and digital connections. Augury provides a crucial element in this transformation, but to truly achieve operational excellence, organizations need to take better advantage of their machine health insights,” explains Chris Dobbrow, VP of Strategic Business Development at Augury. “Our partnership with IFS Ultimo bridges the gap between data and action, enabling organizations to proactively manage their assets, drive efficiency, and remain competitive.”

To learn more, or to start leveraging the integration, contact Augury or IFS Ultimo.