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The Importance of Calibrating Fixed Gas Detectors for Safety

Fixed gas detectors play a critical role in safeguarding people, places, and the planet against potentially life-threatening gases in environments ranging from high value industrial complexes to laboratories and hazardous confined spaces. However, to ensure their accuracy and reliability, regular calibration is an indispensable practice.

Calibration is usually a two-step procedure – the zero and the span. In the first step, the sensor is zeroed using ambient air after confirming that the target gas is not present or by using a suitable gas from a cylinder. The second step is to expose the instrument to the calibration gas that contains a known concentration of the target gas the sensor is designed to measure. The readings are then adjusted to match these values.

Whether an instrument warns and/or alarms at the proper time depends on its ability to translate the detected concentration of a target gas into an accurate reading

During calibration, gas detectors perform relative measurements. Rather than independently assessing the quantity of gas present, they measure the concentration of targeted gas within a test gas mixture by comparing real-time sensor response to the sensor’s response to a known concentration of target gas that the instrument is configured to detect and measure. This “known concentration” test gas serves as the instrument’s measurement scale, or reference point.

So, why is this important? Here are a few reasons to consider:

1. Ensuring Gas Measurement Accuracy and Reliability

A gas detector that isn’t accurately calibrated can lead to mis-readings, false alarms, and inadequate responses to hazardous situations. Proper calibration fine-tunes the detector’s sensor(s) to maximise speed of response, measurement accuracy, and provide reliable information to personnel required to make informed decisions in critical moments.

2. Meeting Regulatory Compliance

Safety regulations and standards are in place for a reason – to protect people, property, and the environment from potential hazards. Many industries are subject to these regulations that dictate the calibration and maintenance of gas detectors.

3. Mitigating False Alarms and Detection Failures

A poorly calibrated gas detector can lead to unnecessary evacuations, disruptions, and complacency due to frequent false alarms. Conversely, improper calibration might render a detector insensitive to dangerous gas levels, leaving people and operations vulnerable to potential harm.

4. Accounting for Changing Environmental Conditions

Fluctuations in temperature, humidity, and atmospheric pressure can impact the performance of these instruments. Regular calibration adjusts for these variables, ensuring that the sensor maintains its accuracy despite ever-changing conditions.

5. Combating Sensor Drift and Aging

Just like any mechanical or electronic component, gas sensors can experience signal drift or degradation over time. When the detector’s current readings deviate from the known reference, proper calibration procedures enable necessary adjustments to the sensor’s output. This adjustment effectively brings the sensor’s response back in line with the original calibration reference, minimising the impact of sensor drift.

6. Upholding Record Keeping and Liability

In the age of accountability, maintaining thorough records of gas detector calibration is a prudent practice. It demonstrates a commitment to safety management and can serve as a valuable resource in case of incidents or accidents. Having well-documented calibration records can potentially mitigate legal liabilities and bolster an organisation’s credibility.

7. Fostering Confidence in Safety Systems

An accurately calibrated gas detector is not just a piece of equipment; it’s a testament to an organisation’s dedication to safety. Regular calibration instils confidence in employees and management that the safety systems are in optimal condition, ready to provide accurate information and timely alerts in case of emergencies.

Conclusion

Routine calibration helps ensure accurate measurements, regulatory compliance, and a reliable defence against hazardous gases. Onsite safety and instrument availability is maximised while mitigating against false alarms at the same time. In a world where safety is paramount, the simple act of calibration speaks volumes about an organisation’s commitment to the well-being of its people and the environment.

Download our whitepaper: https://gb.msasafety.com/trucal#whitepaper

Q-mation adds IFS Ultimo to portfolio to improve customers maintenance & safety IFS Ultimo expands international footprint by extending operations in the United States through a partnership with Q-mation

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IFS Ultimo and industrial software provider Q-mation have signed a partnership to help support customers in the US to benefit from IFS Ultimo’s Enterprise Asset Management / Collaborative Maintenance Management Solution (EAM / CMMS) platform. Q-mation is the world’s largest and most comprehensive sales, support, and training organization for AVEVA software solutions. The partnership allows Q-mation to add IFS Ultimo’s EAM solution to its portfolio and offers maintenance and asset management features to its industrial customers.

Both IFS Ultimo and Q-mation are strongly connected to joint partner AVEVA. For IFS Ultimo, this first reseller partnership in the US is another step in its global growth strategy. In recent years, IFS Ultimo already onboarded AVEVA Select partners in the UK, Spain and Italy. Both companies presented their partnership to their customers at AVEVA World 2023 in San Francisco.

Freddy Vos, VP International Sales and Channel at IFS Ultimo, commented: “The strong combination of the AVEVA and IFS Ultimo solutions allows Q-mation to offer the IFS Ultimo platform across multiple industrial sectors in the US. Customers will benefit from having local access to IFS Ultimo and the expert support and industry knowledge provided by Q-mation. Our solution is well known for rapid deployment, ease of use and seamless integrations. We already have more than 2200 customers across the globe. We are delighted to now serve more customers in the US through this collaboration with our valued and experienced partner, Q-mation.”
Ralph Gordon, Vice President of Expert Solutions at Q-mation added, “We’re proud to be working with IFS Ultimo as its EAM system aligns perfectly with AVEVA’s Asset Management Solutions. The integration with AVEVA Insight and System Platform enables greater business insight through the transference of seamless data connections for optimized productivity, efficiency and safety. The IFS Ultimo partnership helps to build a bridge between production and asset management for our customers and puts them in control of their data and digital transformation future.”

Image description, from left to right: Freddy Vos, VP International Sales and Channel, IFS Ultimo; Ralph Gordon, Vice President of Expert Solutions, Q-mation; Cody Galeggos, Channel Account Manager, IFS Ultimo.

About IFS Ultimo  
IFS Ultimo is a SaaS EAM / CMMS solution from IFS, focused on maintenance & safety and well known for a rapid deployment, ease of use and an unparalleled time to value. IFS Ultimo is part of IFS.

IFS develops and delivers cloud enterprise software for companies around the world who manufacture and distribute goods, build and maintain assets, and manage service-focused operations. Within our single platform, our industry specific products are innately connected to a single data model and use embedded digital innovation so that our customers can be their best when it really matters to their customers — at the Moment of Service™️. The industry expertise of our people and of our growing ecosystem, together with a commitment to deliver value at every single step, has made IFS a recognized leader and the most recommended supplier in our sector. Our team of 5,000 employees every day live our values of agility, trustworthiness and collaboration in how we support our 10,000+ customers.
www.ultimo.com

About Q-mation 
Q-mation has delivered automation solutions in industrial environments since 1987 and is the world’s largest and most comprehensive sales, support, and training organization for AVEVA software solutions. The company is a leader in applying software and technology to build sustainable solutions, ranging from SCADA through MES. Q-mation serves corporate end-users, single manufacturing sites, and OEMs and often partner with system integrators to bring world-class software solutions and best practices to the world.
www.q-mation.com   

Enerpac Workshop Presses - Combine Safety and Superior Performance

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Enerpac announces two series of workshop presses—the XLP-Series H-Frame Workshop Presses and VLP-Series Benchtop Presses. Whether for differential assembly in the automotive industry, gear components assembly in the aerospace industry, or bearing maintenance in the mining industry, the Enerpac VLP and XLP presses offer superior performance. 

New XLP-Series Workshop Presses
Available in 25-, 50-, and 75-ton models, the XLP-Series Workshop Presses feature adjustable side-to-side cylinder movement, a locking winch for easy height adjustment of the press bed, and high-performance manual, pneumatic or electric pump options with remote valve operation. The 25-ton press has a simple, welded design and the 50- and 75-ton presses have an open frame and bolted design. The 50-and 75-ton models come standard as unassembled kits, and include complete press frame, winch, cylinder, pump with gauge, couplers and hose. 

New VLP-Series Benchtop Presses
Enerpac VLP-Series Benchtop Presses work with manual or air pumps. They feature a welded frame and are available in 10-ton models.

To learn more about the Enerpac VLP and XLP Presses, visit www.enerpac.com

Historic pub strikes it lucky with horseshoe manufacture

When the Horseshoe Inn, a historic 17th Century pub in a small Staffordshire village, wanted a large horseshoe symbolic of its name made from heavy-grade steel, it was unsure where to turn. Fortunately, businessman and Managing Director of successful manufacturing company Hi-line Industries, Steve Smith, lives nearby. Hi-line takes its support for local businesses very seriously, particularly ones that play such an important role in the community. The company therefore gladly stepped in to manufacture the customised horseshoe on the pub’s behalf free of charge.

Hi-line Industries is a UK-based leader in the design, manufacture and installation of energy-efficient compressed air purification equipment, serving a rapidly expanding customer base across the UK. Although manufacturing large horseshoes is far from core business, the company has the know-how and expertise to turn concepts into reality at its production facility in Burton-upon-Trent. Notably, Hi-line is a proud supporter of the ‘Made in Britain’ campaign, highlighting the passion around British brands and UK manufacturing.

“Our facility in Green Street is only a couple of miles from the village of Tatenhill, home to the Horseshoe Inn,” explains Steve Smith. “I know the pub personally because I live not far away. So when I heard about their requirement, I knew we could help. As a successful company prospering on a national scale, we always try to show our support for enterprising local businesses. We were very pleased to assist such an important establishment as the Horseshoe Inn, which has been at the heart of its community for centuries.”

                                                                                                                                                                        Continued ……

The Horseshoe Inn is a family-friendly pub with a warm atmosphere that makes everyone feel at home, whether they are drinking or dining. This old village coaching inn, which dates back to the late 1600s, retains much of its charm despite extensive renovation over the years. The wood-panelled public bar has a homely feel and several of the linked rooms feature low-beamed ceilings and assorted breweriana. The new horseshoe custom-made by Hi-line Industries from 10mm thick steel will make a striking addition to this landmark structure and, hopefully, bring lots of luck for many years to come.

Further information is available from: Hi-line Industries Ltd,

Green Street, Burton on Trent, Staffordshire  DE14 3RT

Telephone: 01283 533377                                           Fax: 01283 533367              

e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.                      www.hilineindustries.com

How do you know when a bearing needs to be replaced?

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The ISO guidelines for acceptable levels of vibration in rotating machinery form a very good basis for setting alarm levels in the context of Condition Based Maintenance (CBM). These levels can be used to indicate machine status on a “traffic light” basis, e.g. acceptable (green), warning (amber) and critical (red).

By intention, the ISO frequency range of 2Hz to 1kHz covers the vast majority of rotating machinery typically encountered (motors, pumps, fans etc.) and allows the detection of faults such as unbalance, misalignment and looseness. Uncorrected, these faults will lead to premature bearing failure and potential damage to the machine.

But what about the bearings themselves? How do you know when a bearing needs to be replaced?

The ISO frequency range will not detect bearing wear, unless the bearing is so badly worn it is on the brink of collapse. This is because most bearing noise results from high frequency vibrations of the bearing elements and is in the frequency range above 1kHz, the upper limit of the ISO range. This high frequency vibration is the typical “whine” you hear from a worn bearing. In practice, it is usually inaudible until the bearing becomes so bad it is probably about to fail. Fortunately, a vibration analyser can detect the inaudible bearing noise well before it gets to that point.

Although there are no formally agreed standards for acceptable levels of bearing noise, some “de facto” industry standards have been established to quantify bearing condition, such as the use of Bearing Damage Units (BDU). The BDU reading is the measured high frequency (above 1kHz) vibration acceleration in units of g (Earth’s gravity) multiplied by 100. So 1g = 100 BDU, 2g = 200 BDU etc.

As a “rule of thumb” for typical induction motors running at roughly 1500 RPM in Europe (1800 RPM in North America) vibration analysts consider 1g (100 BDU) as the threshold for a worn bearing. Hence, it is tempting to think of BDU as “percentage bearing wear” for typical motor run speeds. Manufacturers of CBM instruments will sometimes give guidelines for acceptable levels of bearing noise, but to diagnose a bad bearing the best thing to do is to look at the TREND of the BDU readings.

The example VibTrend plot shown here shows the BDU readings of a large bearing on a wire saw. The vibration readings were taken roughly every two weeks and the increase in BDU values as the bearing begins to deteriorate is very clear. The decision was taken to replace the bearing after the reading reached a level of roughly 350 BDU. The readings taken after the bearing was replaced then established an approximately 30 BDU baseline for a “known good” (i.e. new) bearing.

Comparisons between “known good” bearings and bearings that are known to be worn soon enables patterns to be observed. In the case described here, alarm levels for similar bearings were subsequently set at 100 BDU for a Warning (amber) and 200 BDU for Critical (red).

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Fortunately, simple-to-use, low-cost vibration analysers capable of trending readings are now available. The TPI 9080 (from £1,100) comes complete with VibTrend PC based trending and reporting software that includes automatic report generation and email notification of alarms, implementing a full CBM solution. The TPI 9080 can store lists (routes) of machines to be measured (up to 1,000) with full vibration waveform and frequency spectrum capture for each.

Routes and readings can be transferred between the TPI 9080 and the included, license free, VibTrend software in a variety of different ways.  Via the included USB docking cradle, wirelessly via Bluetooth or remotely via a Bluetooth link with a smart phone or tablet running the free TPI Bridge App. This allows service personnel to receive routes and return readings, no matter where they are in the world.  

For more information please contact TPI Europe’s head office on +44 1293 530196 or take a look on the website at www.tpieurope.com or email This email address is being protected from spambots. You need JavaScript enabled to view it.

ARCO PROFESSIONAL SAFETY SERVICES INVESTS IN EXPANSION OF EQUIPMENT HIRE CAPABILITIES

Arco Professional Safety Services, the UK’s leading safety products and services provider, is expanding its equipment hire capabilities nationwide with new funding into four fully stocked hire centres in key locations across the UK.

The expansion of hire products will enable customers to access a wider range of hire equipment from leading specialist suppliers, including quality-assured confined space, gas detection, respiratory protective and other fall arrest prevention equipment. All hire orders will be available direct from the Arco Bracknell, Doncaster, Linlithgow and Warrington Safety Centres or can be ordered and collected at local Arco stores via a new collection service. 

Arco offers two types of hire solutions, standard hire, for short term requirements with a minimum contract of one week that can be extended as needed and contract hire that is offered for longer terms, up to five years, that also includes inspection, servicing and maintenance of equipment during the hire term.

Alongside this expanded hire proposition, customers can also purchase any of the equipment from Arco’s range of safety products should they require a permanent solution.

Gareth Liptrot, Hire & Maintenance Manager, Arco Professional Safety Services said: “As experts in safety, we are committed to providing a joined-up approach for customers offering accessible, high-quality equipment that can be acquired in the most convenient way.

“Our increased investment in hire stock at our nationwide Safety Centres and our new store collection service demonstrates our commitment to improving customer convenience and will enable greater access to quality stock and ease of service for any job our customers are undertaking.”

To find out more about Arco’s comprehensive hire offering, visit: https://www.arcoservices.co.uk/equipment/equipment-hire

Preventing Fire and Explosions Aboard Commercial Ships

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Fire and explosions are among the most significant dangers aboard any sizeable vessel. This is true for all seafarers, including military, commercial, and privately owned ships. All crew members should be well trained in fire fighting, but the best training is on how to prevent fires from happening in the first place. The proper choice of portable LED lighting can reduce the risk of fire and explosions.

Three elements are needed for a fire to occur: a fuel source, oxygen, and an ignition source. The ignition source is the easiest part of this equation to remove using Intrinsically Safe (IS) lighting. So what does IS actually mean? Generally speaking, an IS-rated portable light is carefully designed and manufactured so that it cannot release enough electrical and thermal energy to ignite combustible gases or vapors.

One of the many IS rating requirements is that lighting must be constructed of a non-sparking substance. Engineered polymer is the most commonly used material. Because of its saltwater and chemical corrosion resistance properties, this makes polymer ideal for maritime use. Additionally, IS lights must be completely waterproof, another feature sailors appreciate. Innovative Manufacturers that create lighting specifically for use aboard commercial ships also add useful features such as rare-earth magnets and dual lights. In smoke-filled environments, dual lights allows the user to activate the spotlight and downward-facing floodlight simultaneously, navigating around trip hazards while also lighting the path ahead.

The combination of magnets and a floodlight gives the ability to attach IS portable lighting to the bulkhead to operate equipment hands-free without the intense glare of a spotlight.

Because of the knowledge, time, and expense required to engineer and produce IS-certified lighting, few companies achieve this. Nightstick is a global manufacturer of over 50+ Intrinsically Safe LED lighting products used worldwide in 70+ countries. Find a distributor near you at www.nightstick.com

UE Systems revolutionizes Bearing Maintenance with the launch of OnTrak Wireles

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UE Systems, a pioneering force in developing ultrasonic detection instruments and solutions for maintenance and reliability, unveils its latest innovation – the OnTrak Wireless system.

This cutting-edge solution transcends traditional bearing health monitoring by actively preventing failures through precision autonomous lubrication, addressing lubrication-related issues which account for a significant portion of premature bearing failures. This cutting-edge innovation arrives hot on the heels of the recently launched Ultraprobe 15,000, showcasing UE Systems' relentless pursuit of innovation in maintenance and reliability solutions.

"The OnTrak Wireless system is set to redefine the approach to bearing maintenance," said Blair Fraser, Vice President of Business and Technology Development. "Beyond merely monitoring for defects, the OnTrak Wireless system proactively prevents them, leveraging autonomous precision lubrication. Considering that lubrication issues are implicated in up to 80% of premature bearing failures, this technology is a game-changer."

The OnTrak Wireless system integrates the new 950BT Wireless Sensor, which combines ultrasound, vibration, speed, and temperature monitoring into a single unit. This multi-faceted approach to asset monitoring not only identifies but actively prevents the most common causes of bearing failure.

"Our ultrasound-first strategy is elevated by the inclusion of vibration and temperature metrics," Fraser continued. "The 950BT sensor is unmatched in its ability to detect and prevent asset defects, offering a new level of confidence in bearing health assessments."

UE Systems' OnTrak Wireless is powered by UE Insights, an AI-driven platform that offers adaptable, browser-based visualizations for any asset. With its advanced anomaly detection, UE Insights empowers users to identify and address unusual operational patterns early, before they lead to failures.

"We're not just innovating; we're reimagining the role of ultrasound in maintenance," Fraser emphasized. "The OnTrak Wireless system, backed by our extensive experience and commitment to excellence, represents the future of predictive maintenance."

For more information about UE Systems and the OnTrak Wireless system, please visit https://www.uesystems.com/en-gb/product/ontrak-wireless/

Coming soon - the go-to place to source manufacturing essentials

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Southern Manufacturing & Electronics 2024, the most comprehensive annual industrial exhibition in the UK calendar and a major pan-European showcase for new technology, opens from 6th to 8th February. This year’s show is breaking new ground, with the highest ever number of stand bookings by overseas companies. The show moved to its present location in 2008 and was the first event to be held in the world-class Farnborough International Exhibition & Conference Centre when it was built in 2018.

The stands are split approximately equally between exhibitors operating in two distinct industries, mechanical engineering and the electrical/electronic sector. There is no demarcation between the two areas, however, so visitors are able to walk freely between stands and perhaps discover unfamiliar yet useful things they were not expecting. Hosting so many exhibitors operating at the forefront of technology, the show is an ideal venue for addressing diverse sourcing requirements quickly and efficiently.

It is an event that attracts large manufacturers, but SMEs also find it very accessible. The show operates a policy of open access that discourages big-name firms from dominating the space to the detriment of smaller vendors. The resulting mixture gives the show a unique, vibrant atmosphere that is unlike that of any other. Testament to this, and to its effectiveness as a place to do business, is the very high rate of return bookings since the show started in 1997.

It is a must-attend event for anyone involved in the design, production, procurement or management to see all the latest in business and engineering software, production and planning aids, oil and coolant supply, workshop equipment, dust and fume extraction, humidity control, workplace storage systems, bespoke case and foam manufacture, plastic packaging, injection moulding, hand tools, adhesives, industrial flooring, waste removal and recycling, training, freight services and financial consultancy.

There will be companies offering mechanical, electrical, electronic, electromechanical, hydraulic and pneumatic components, SMT technology, PCB assembly and box build, mechatronics assembly, plastic injection and rubber moulding services, cables, connectors, sensors, drives, encoders, fasteners, pressings, wireforms, springs, gaskets, and more. They will be joined by suppliers of machine tools, tooling, workholding and other production hardware, test, measurement, inspection and metrology equipment, and sundry materials from exotic alloys to composites.

Additive manufacturing continues its progress towards becoming a mainstream manufacturing technique and there will be many companies offering production platforms, consumables and subcontract services. Automation will also feature strongly, driven by a skills shortage in Britain and across Europe. Manufacturing industry is facing a battle to recover from the impact of Brexit, supply chain disruption, and soaring energy costs. To help alleviate these difficulties, Industry 4.0 implementation, robotic applications, cobot (collaborative robot) loading of machines, reshoring of production, and new technologies such as green energy and power-saving machinery will all be prevalent.

There will be a programme of free technical seminars over the three days to give visitors and exhibitors alike valuable learning opportunities, with a focus on the technical, managerial and environmental issues facing manufacturers. Presentations will include advice for small manufacturers looking to improve their relationship with customers, how to enhance a sales team's performance, CE and UKCA marking compliance, sustainable practices in manufacturing, and management skills coaching including how to address the challenges of hybrid working.

Southern Manufacturing & Electronics 2024 will co-locate with AutoAero, a specialist theme within the exhibition devoted to aerospace and automotive engineering. There is ample car parking and the site is well served by road and public transport links. A regular, free bus service runs between Farnborough’s two railway stations and the showground. Admission and parking are also free of charge. More information and tickets are available from www.industrysouth.co.uk

MachineSafe Compliance - Discover the benefits.

 

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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.

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

machinesafe.co.uk

01793 547018

Decarbonising the Food and Drink Manufacturing Industry

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.

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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.

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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.

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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.

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 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.

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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

 

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