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Unison Ltd, the UK-based inventors of all-electric tube manipulation, celebrated their 50th anniversary with a big birthday bash at their Scarborough HQ on Wednesday, 24th May 2023.

Just short of 100 customers, colleagues, friends and members of the ‘Made In Yorkshire’ trade group attended the event, which began with a hearty brunch and a warm welcome by Unison’s joint managing director, Alan Pickering.

Technology talks and machine tool presentations followed. These included demonstrations of Unison’s ultra-precise, all-electric Breeze range of tube bending machines, as well as fibre laser cutting machines from Unison’s sister company, Nukon Lasers UK. Unison’s newly released Opt2Sim Scan hand-held 3D tube scanning system - the latest addition to the company’s advanced Opt2Sim Suite of tube simulation software - also attracted a great deal of attention. The event concluded with a buffet lunch, followed by ice creams in the glorious Scarborough sunshine that graced the day.

From left: Alan Pickering and Julian Kidger – Unison Ltd’s joint managing directors.From left: Alan Pickering and Julian Kidger – Unison Ltd’s joint managing directors.

“I’d like to thank everyone who attended and helped make our 50th anniversary celebrations such a resounding success,” comments Alan Pickering. “It was fantastic to meet customers and friends old and new – many of whom had travelled a considerable distance to celebrate with us. I’d also like to thank every member of the incredible Unison team for the hard work they put into making the day possible. Here’s to another 50 years of intelligent tube technology!”

Unison Ltd: intelligent tube technology

Established in 1973, Unison Ltd is the UK’s leading manufacturer of tube and pipe bending machines and continually innovates the tube and pipe bending marketplace. The company manufactured the world’s first all-electric tube bender in 1994, followed by the world’s first all-electric multi-stack tube

bender, then the world’s largest all-electric tube bender for the shipbuilding industry. Available in single-stack, multi-stack and right/left varieties, Unison machines are delivered to more than 20 countries globally. Unison’s tube bending software is recognised as the most user-friendly control system for tube bending machines. The software is written and supported by Unison, ensuring complete control of its evolution, with no need for third party support.

www.unisonltd.com

Offshore engineers Blackfish have today [Thursday May 25] launched a Scottish arm to support the fast-expanding offshore wind sector – with the goal of helping operators accelerate innovation and drive down cost.

  • Goal to accelerate innovation and drive down cost.
  • Dedicated Scottish team aims to expand in months ahead.

The Bristol-based engineering specialists already have a long track record in marine renewables in Scotland, working closely with wave and tidal pioneers Mocean Energy and Orbital, alongside a growing portfolio of offshore wind clients.

2023 05 24 100851They now plan to ramp up their offering to Scotland’s burgeoning offshore wind pipeline with a dedicated team based in Aberdeen and Edinburgh led by senior engineers Nick Del-Greco and James Hastie, and strategic advisor Stuart Brown.

Commenting on the new setup, company managing director Jonathan Powell says:

“The rapid expansion of offshore wind in Scotland, in particular the ScotWind round, is creating strong demand for solution-focussed engineers who can partner with developers to address real-life complex engineering challenges – with the clear goals of improving safety, accelerating innovation and driving down cost.

“Already we are working with two of the three largest wind turbine OEMs and nine of the world’s biggest offshore wind developers, and are actively developing bespoke, innovative designs and technology to improve efficiency and lower costs for the sector.

“We are also engaged with innovation bodies including Wave Energy Scotland, the Carbon Trust and the Offshore Renewable Energy Catapult to develop industry-standard products in areas including electrical connections and moorings.”

Senior mechanical engineer James Hastie says:

“We believe our knowledge of tackling problems in the offshore environment is second to none and the creation of a distinct Scottish operation enables us to be closer to our customers, deliver content locally and create opportunities to further expand our offering north of the border.

“These are really exciting times to be involved in offshore wind engineering.”

About Blackfish

Blackfish is forged from years of innovative technology development in the tidal stream industry. From our formation in 2016, we have been driven to impart our hard-earned experience, knowledge and skills to the betterment of the offshore renewable energy industry. We are now one of the UKs leading names for engineering design and development services in Tidal, Wave and Offshore Wind sectors.

www.blackfishengineering.com

Sulzer has recently signed an agreement with major lactic acid (LA) producer, Jindan New Biomaterials (Jindan), to enable the production of polylactic acid (PLA), a biobased plastic. Jindan will utilize Sulzer’s licensed PLA technology at its new manufacturing plant in Henan Province to produce up to 75’000 tonnes of PLA per year, mainly to be used for food packaging, molded goods and fibers production. Sulzer will also provide extensive service support to ensure a seamless start.

2022 05 17 104600Jindan’s new bioplastic facility will produce PLA in a variety of grades to support the expanded use of bioplastics in several sectors in China, including the textile and package manufacturing industries. To enable the company’s transition towards more sustainable, circular practices, Sulzer Chemtech will design and supply its key proprietary PLA technology, while further providing extensive engineering and technical support and field services as the manufacturer commences operations.

Sulzer’s Executive Chairwoman Suzanne Thoma said: “Our leading technologies are currently used at the vast majority of existing PLA facilities worldwide and support the increased adoption of circular manufacturing practices and sustainable materials. We are pleased to collaborate with Jindan New Biomaterials to meet ever-increasing market demand for bioplastics.”

Mr. Shi Congliang, President of Jindan New Biomaterial, added: “By investing in Sulzer’s PLA solutions, we are taking key, strategic steps to advance our competitiveness in the booming biopolymer industry and drive the use of greener plastics. Thanks to its comprehensive expertise in the PLA value chain and all the stages involved, Sulzer Chemtech is an extremely valuable partner. We look forward to installing the equipment and starting-up our enhanced operations.”

Sulzer is a global leader in fluid engineering and chemical processing applications. We specialize in energy-efficient pumping, agitation, mixing, separation, purification, crystallization and polymerization technologies for fluids of all types. Our solutions enable carbon emission reductions, development of polymers from biological sources, recycling of plastic waste and textiles, and efficient power storage. Our customers benefit from our commitment to innovation, performance and quality through our responsive network of 180 world-class manufacturing facilities and service centers across the globe. Sulzer has been headquartered in Winterthur, Switzerland, since 1834. In 2022, our 12’900 employees delivered revenues of CHF 3.2 billion. Our shares are traded on the SIX Swiss Exchange (SIX: SUN). www.sulzer.com

Consumers are demanding: They want quality and speed at the right price, and they expect the manufacturing world to deliver. As organizations everywhere try to meet evolving consumer requirements—all while managing safety, efficiency, and logistics within their facilities—each one faces the looming threat of competitors closing in. With so much on the line, manufacturers are challenged to adopt smart approaches that keep their businesses both profitable and competitive.

More and more, these approaches are being influenced by the prospect of game-changing automation. By integrating smart automation solutions, manufacturers can achieve the kind of operational outcomes that lead to sustainable bottom-line success. In fact, sales of industrial automation equipment, including fixed and flexible options, are on the rise—an upward trend that’s expected to continue as innovation, advancement and the entire industry landscape mold to the needs of the market.

  1. FIXED VS. FLEXIBLE AUTOMATION

Fixed automation, sometimes called hard automation, refers to an automated production process with a “fixed” sequence of operations determined by the equipment’s configuration. Essentially, commands are programmed into the machine to operate its cams, gears, wiring and/or other hardware that is not easily changed over from one product style to another. Fixed automation enables high production rates and is suitable for large-volume products of identical specs. Examples include pneumatic (air-driven) devices, hydraulic machines, electric cylinder assemblies, cartesian pick and place robots, and parts feeding equipment. These options can be leveraged as standalone automation or in tandem with industrial robots.

Flexible automation, also known as robotics, provides the opportunity to accommodate changes and repurpose automation solutions for fluctuating needs. Industrial robots can be programmed to perform multiple functions for products of varying sizes and materials. Because reprogramming the equipment in flexible automation is performed at a computer terminal (not on the production equipment itself), there is no need to group identical products into batches. A mixture of different products can be produced one right after another. Common applications include welding, material handling and machine tending, as well as picking, packing and palletizing.

For manufacturers considering whether new or additional automation might fit into their current operations, it’s essential to understand how this investment can positively impact the business. Here, we’re breaking down seven of the most compelling ways leveraging automation can maximize manufacturers’ competitiveness in the industry.

1. MANUFACTURING AUTOMATION REDUCES LABOR COSTS.

According to the U.S. Department of Labor’s Bureau of Labor Statistics (BLS), unit labor costs (the total labor costs required to produce a unit of output) rose in the vast majority of manufacturing industries in 2019. Of the 51 industries in durable manufacturing, 45 experienced rising unit labor costs. Of the 35 industries in nondurable manufacturing, 32 recorded rising unit labor costs.

For so many companies, labor is the predominant cost in manufacturing a product, not to mention the most difficult one to manage. The most obvious way that automation helps slash this expense is by requiring fewer workers to produce the same number of manufactured goods. Fewer workers means less monetary allocation for not only payroll, but also employee taxes, healthcare benefits, insurance and other related overhead costs. Of course, this is just one aspect of a much larger labor cost benefit.

Take the high cost of employee acquisition and turnover. For one thing, worker shortages are a real and present challenge in some areas. Recent findings from the BLS Job Openings and Labor Turnover Survey show that the number and rate of total U.S. job openings have increased to 6.6 million (+617,000) and 4.5 percent, respectively. There is also the vastly increasing number of Baby Boomers (born between 1946 and 1964) approaching retirement age. In less than 10 years, all of the workers in this generation will be 65 years or older.

At an estimated 73 million, this generation is one of the largest living age groups, second only to millenniums—a population highly unlikely to gravitate toward production roles in manufacturing facilities.

What does this all mean? Well, particularly for jobs that are demanding, dirty, dangerous or downright unpleasant, the time and expense it takes to fill open manufacturing positions amid current employment conditions can become a major burden—one that automation plays an immense role in easing.

Finally, there’s the cost of absenteeism, which results in a lack of consistency and predictability in terms of planning for production shifts. When workers unexpectedly leave early or call out, it can cause significant and costly disruption to production uptime.

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2. MANUFACTURING AUTOMATION MAXIMIZES CAPACITY UTILIZATION.

The capacity utilization rate is an important operational metric for manufacturing companies, as it assesses their current operating efficiency. Automation supports higher rates of capacity utilization by fostering greater, faster output without requiring additional per-unit expense.

For instance, if you automate an existing process that was relying on human workers for operation, now you have the ability to produce through lunches and breaks, and even in the event of employee sickness or no-shows. In fact, you could potentially run two 10-hour shifts via the automated process and achieve the same output as you might over a 24-hour period consisting of three 8-hour shifts (given, of course, that each person will require at least one hour of non-production time for lunch and breaks).

Automation works tirelessly around the clock. It doesn’t get sick, get distracted, require vacation time or take breaks. It is reliable and consistent.

And if demand necessitates a ramping up of your production output without increasing your production time, automation gives you the opportunity to produce more quickly—minus the need to invest in additional production equipment and/or workers.

3. MANUFACTURING AUTOMATION IMPROVES QUALITY AND ACCURACY.

Manufacturing automation streamlines repetitive tasks and minimizes margins of error. Adoption of modern systems has become critical for maximizing Cpk and alleviating manufacturers’ quality, consistency and waste issues, manifesting the following outcomes for those who embrace smart solutions.

  • Repeatability & Precision:

Especially in the life sciences arena, such as pharmaceutical and healthcare manufacturing, human error is a big concern. It is essential for these products to have zero defects because people’s health and lives are at stake. With the support of automated solutions that make ultimate repeatability and precision a reality, you can mitigate the risk to both consumers and the organization at large.

  • Product Safety & Viability:

Particularly in the food and beverage industry, production and handling processes that rely on human workers carry increased risk of introducing contamination into the environment, which ultimately endangers the final product. Automated systems minimize human interaction with the product, thereby lessening the potential for contamination by germs, pathogens or foreign objects that can result in discarded food, complex recall processes, loss of consumer trust and legal liability.

  • Reduced Waste:

When it comes to applications that involve uniformity and quality, human error has the potential to incur substantial monetary losses. Consider, for instance, companies in the faucet industry that utilize workers to fulfill the polishing process. Because humans, by nature, are prone to making mistakes, a certain amount of products will bear defective surface finishes and must be discarded. Automation eliminates this waste.

  • Mollified Material Damage:

In industries where expensive materials and equipment are handled by humans, there’s ample opportunity for error to result in costly damage. Fiber optic cable, as an example, is extremely fragile and, if mishandled by a worker, can cost thousands of dollars. There’s also the risk of humans dropping heavy parts, a mistake that can cause damage to the part itself, expensive production equipment, or even a workplace injury.

  • Unrivaled Skill & Consistency:

Think about the consistent motion required for production processes like painting and welding. Automation affords a level of technique and uniformity that humans are simply incapable of matching.

4. MANUFACTURING AUTOMATION SUPPORTS SAFETY AND ERGONOMICS.

According to the U.S. Department of Labor’s Occupational Safety and Health Administration (OSHA), work-related MSDs are among the most frequently reported causes of lost or restricted work time. MSDs, or musculoskeletal disorders, affect the muscles, nerves, blood vessels, ligaments and tendons.

Workers in many different industries and occupations can be exposed to risk factors at work, such as lifting heavy items, bending, reaching overhead, pushing and pulling heavy loads, working in awkward body postures and performing the same or similar tasks repetitively. Exposure to these known risk factors for MSDs increases a worker’s risk of injury.

In production facilities lacking automation, workers may be subjected to safety and ergonomic concerns such as:

  • Physical stress
  • Strain
  • Overexertion
  • Repetitive motion
  • Awkward postures
  • Heavy lifting

These can cause employees to experience intractable pain, an inability to work or physical conditions that necessitate medical care and time off—all of which results in production downtime and higher costs for the organization. On the other hand, automated solutions improve workplace safety while optimizing workflow processes.

By creating a more favorable and ergonomic working environment, automation has the potential to retain talent and limit liability. Safer, less rough conditions, like those cultivated by replacing certain human-performed tasks with machine-operated ones, minimize the risk of seeing a revolving door of workers, the challenge of constantly training new people, the ongoing need to attract employees for hazardous and undesirable jobs, and the liability inherent in unsafe surroundings.

5. MANUFACTURING AUTOMATION ACCOMMODATES SOCIAL DISTANCING AND FULFILLMENT DEMANDS.

In the midst of a global pandemic, with its rippling social and economic impacts, the market for manufacturing automation and industrial robots has exploded. FANUC, the largest maker of industrial robots in the world, has seen its volume demands flourish.

Why is this the case? One big reason is the now critical need for manufacturers to safely space out their workers and limit human interaction. Anywhere people are working in small, confined or heavily populated spaces, there’s increased risk for exposure to a contagious virus. And just one positive test result can lead to production declines or even a complete shutdown. Manufacturing automation solutions support a reduction in the manpower needed to occupy these spaces, thereby mitigating the overall risk of infection.

In addition, there’s automation’s capacity to meet rising fulfillment demands. Especially with regard to product categories that have skyrocketed in response to the onset of stay- at-home guidelines and other pandemic-related nuances, production requirements have amped up for some manufacturers. Automation provides the platform for meeting increased demands and tightened turnaround times.

  1. THE ROLE OF ROBOTICS TECHNOLOGY IN THIS ERA OF DYNAMIC INNOVATION

Robots are already deployed across many segments of the supply chain, and the industry expects to see an explosion in the number of robots working in warehouses and DCs as the growth of e-commerce fulfillment continues to rise. Even before the global pandemic and coinciding shifts in consumer behavior, decreasing population, and increasing demand, the implementation of robotics and automation was expected to expand as companies look for ways to remain productive and competitive.

Once considered a futuristic trend, autonomous robots are quickly becoming the useful and reliable technology for the logistics industry. Autonomous mobile robots (AMRs) are proving to be a disruptive robotic solutions technology that are increasing efficiencies, providing significant cost savings, and mitigating risks associated with human resources. A variety of AMRs are currently in use. Some are considered ‘collaborative’ — that is, designed to work with and around people — and others non-collaborative.” Additionally, this technology is working in both structured and non-structured environments, making the implementation more advantageous across several industries.

6. MANUFACTURING AUTOMATION CREATES JOBS AND MINIMIZES RELIANCE ON GLOBAL OUTSOURCING.

There’s a changing perception of automation occurring among the general public. The common judgement, particularly after the last recession, used to be that automation takes jobs away from the American workforce. Now, we’re starting to see a shift in that mindset.

Yes, automation definitely replaces some of the unskilled labor force. By leveraging it to keep factories up and running, however, you’re also sustaining valuable jobs like administrative, human resources, and cleaning and maintenance, not to mention the skilled workers required to program and manage all of the new technology. In essence, manufacturing automation has the potential to create both vast opportunities for employment and a greater reliance on our own domestic resources.

Remember, the U.S. still has the cheapest and most consistent energy supply. And the consumer is here. It’s always cheaper to manufacture closer to your consumer. Manufacturing your product locally, where it is purchased, gives you a huge competitive advantage in supply chain management. Automation enables manufacturers to keep production onshore, giving U.S. companies a competitive edge in the global market.

7. MANUFACTURING AUTOMATION BOOSTS OVERALL PROFITABILITY.

The evolution of manufacturing automation has transformed once difficult, slow, and hazardous production tasks into remarkably safer and more productive ones. As automation in manufacturing continues to advance in sophistication, so do the advantages of leveraging such opportunities in facilities across the industry. Although the prospect of adopting a modernized approach to routine operations can seem daunting, the profitability payoffs are well worth the leap.

Given all of the factors mentioned already, it stands to reason that automation can produce and get items to your customers more efficiently, thereby increasing your profit margins— gains that are poised to continue well into the future. Here’s a more specific breakdown of how some of the previously highlighted competitive advantages amount to cost savings and expanded profitability.

  • Labor Reduction: With the right automation solution(s), your organization will require less manpower for its operations, including reduced HR and overhead costs.
  • Machine Utilization: Production numbers tend to drop as workers become tired or call out, whereas automation has the ability to maintain consistency throughout any shift, from beginning to end. This means your line is set to run more efficiently and without the need to replace equipment as frequently.
  • Quality Improvements: With the precision of an automated process, you’re positioned to produce less scrap or waste, an important measure of cost savings.
  • Ergonomic Savings: Automation minimizes the costly risk of workplace injury, including time off, workers’ compensation, increased insurance premiums and potential compliance fines.
  • Worker Retention: When automation performs the unfavorable types of tasks once assigned to human workers, it can foster a more amenable work environment. Happier employees generally equate to less turnover, which leads to a more lucrative bottom line.
  1. DESIGNING AN AUTOMATION SOLUTION FOR YOUR MANUFACTURING NEEDS

Given the wide span and nature of ways to derive value from automation, it can be argued that just about any manufacturing operation has the potential to glean a competitive edge from embracing it. And even though automation was too expensive for smaller companies to implement some 15-20 years ago, this has completely changed over time. Now, automation is suited to organizations of all sizes. As long as you’re seeking to lower cost and improve efficiency, automation is worth your consideration.

The way in which your company ultimately chooses to leverage automation should depend largely on your business goals and operational requirements. Regardless, the opportunities for organizational competitiveness are immense.

Consider partnering with an integrator who will work to understand and accommodate your goals before designing an automation system that fully supports them. Whether you already have detailed specifications for a project or you’re looking for an expert to develop a plan based on your cycle times, product information and overall business objectives, an experienced integrator like Wauseon Machine has the knowledge and expertise to make your integration a successful one.

About Wauseon Machine and Manufacturing

Wauseon Machine and its sister company, McAlister Design & Automation, are industry leaders in robotics automation, tube fabrication equipment, and build-to-print precision machines parts. With 40 years of experience, the company has four separate focus plants dedicated to Tube-Forming Technologies, Robotic Automation, and Precision Machining. Across their plants, they focus on tool development, machine building, automation, and providing contract CNC production machining of volume and custom precision piece parts and components for other companies. Wauseon Machine / MD&A are best in class suppliers of system integration to incorporate automation into a variety of industries, applications and cutting edge technologies for manufacturing. For more information, visit https://www.wauseonmachine.com.

KROHNE, Inc. announces that it will be showcasing the TIDALFLUX 2300 F Electromagnetic Flowmeter, a flow measurement solution ideal for partially filled pipes, at the Florida Water Resources Conference 2023 from May 31 - June 3, 2023, at the Gaylord Palms Resort in Kissimmee, Florida. Attendees can view KROHNE’s unique electromagnetic flowmeters at booth #534.

Visit KROHNE at booth #534 to learn about their meters and measuring solutions

The TIDALFLUX 2300 F provides reliable flow measurement in pipes between 10 and 100 percent full. It features a non-contact sensor that is unaffected by oils and fats floating on the surface. Its smooth surface prevents buildup, minimizing the need for regular cleaning.

Available in diameters to fit pipes up to 72 inches, TIDALFLUX 2300 F has high chemical and an abrasion resistant polyurethane liner to provide exceptional durability. The electromagnetic flowmeter features an integrated, non-contact capacitive level measurement and a Class 1 Division 2 rating for use in hazardous environments. TIDALFLUX 2300 F is an excellent choice for municipal or industrial wastewater transport application, and can also be used for measurement of effluent brine from dredging, mining or sea/well water injection applications.

Wet-calibrated at the factory using a direct volume comparison, TIDALFLUX 2300 F does not require on-site calibration. The meter’s accuracy in partially filled pipes is <1 percent of full scale, and the accuracy in full pipes is <1 percent of the measured value.

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A good choice for use in the presence of hydrogen sulfide (H2S) in wastewater applications, the TIDALFLUX 2300 F replaces open channel measurements with an in-line closed measurement solution that provides a safe and clean working environment. The electrodes are mounted at a height of 10 percent from the pipe bottom, ensuring that they are always wetted to avoid corrosion, which increases electrode life span. The capacitive level sensors are integrated in the liner, and are unaffected by H2S and any residues that may be floating on the water surface or particles in the water.

TIDALFLUX 2300 F is available with the IFC 300 F (PF) remote converter in field housing. This means that the IFC 300’s extended diagnostic functions, including application and device diagnostic as well as out-of-spec tests, are now available for TIDALFLUX. For subsoil installation or applications in areas that can be partially flooded, TIDALFLUX 2300 F can be ordered with an IP68 protection rating which features a special coating.

KROHNE will also have the WATERFLUX 3070 battery powered electromagnetic flowmeter on display as well as the OPTIWAVE 1400 among other measuring solutions. The WATERFLUX 3070’s unique rectangular sensor design provides bi-directional flow measurement over a wide dynamic range and good low flow performance. The water meter’s optimal pressure and temperature sensors allow it to be used in leak detection, quality control, and pressure management systems. The OPTIWAVE 1400 is a 2-wire 24 GHz radar (FMCW) level transmitter for liquids in water and wastewater applications. It is equally suited for continuous, non-contact level measurement of water from springs, rivers, lakes or the sea as well as rainwater, wastewater, sludge or other liquids in storage applications. 

For more information, speak with the KROHNE experts in booth #534 at the Florida Water Resources Conference or visit www.us.krohne.com.

About KROHNE 

KROHNE is a worldwide technological leader in the development, manufacture and distribution of accurate, reliable and cost-effective measuring instruments for the process industries. KROHNE focuses on forming partnerships with its customers to provide them with the most reliable and innovative solutions available in the marketplace. For more information about KROHNE’s complete line of measuring instrumentation for the process industries, contact KROHNE at 1-800-FLOWING (978-535-6060 in MA); fax: (978) 535-1720, email: This email address is being protected from spambots. You need JavaScript enabled to view it., www.us.krohne.com.

PulPac demonstrates efficiency, expands product and barrier portfolio – enabling the network to offer a limited series of production lines with fast-tracked delivery, with production warranties.

Breaking efficiency records on demonstrator line and expanding product portfolio. Swedish innovative packaging company, PulPac, and its partner network are ready to offer production warranties, including a limited batch of ready-to-order production lines with fast-tracked delivery in six months.

PulPac reports multiple breakthroughs from within its partner network and across its Dry Molded Fiber technology platform. In a recent multi-shift production run for one of its licensees, PulPac reached an 85% equipment efficiency with its first-generation pilot Modula line at its technology center in Sweden.

"We know the Modula well and know of its capabilities, but numbers like these prove that the Dry Molded Fiber manufacturing process is reliable and scalable," says Kristian Ward, Operations Manager at PulPac. "The team here at the tech center, TechTribe, and everyone else involved has worked hard to achieve extraordinary results like these. I'm certain we'll improve the efficiency even more as the Modula platform already has ordered second-generation production lines that are entering production worldwide with our licensees."

Together with recommended EU turnkey partner, TechTribe, PulPac has secured fast-track delivery for a limited batch of validated production lines. These production lines are ready for order in May and can be shipped within six months, enabling customers to expand their sustainable packaging journey quickly and with warranties.

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PulPac's patented Dry Molded Fiber technology is a groundbreaking manufacturing process for turning renewable pulp into high-performance packaging materials with a lower climate impact than wet-molding and plastic processing. The products are fully biodegradable, recyclable, and compostable, which is what packaging producers need to tackle the sustainability challenges they face.

At the same time, the team responsible for PulPac's Highway program confirms an expanded portfolio of validated, ready-to-produce, Dry Molded Fiber products. The Highway program now includes complete cutlery sets with multiple barrier solutions for hot and cold foods and complementing trays with new tableware designs, including a ≥45 mm deep salad bowl. The added groundbreaking coffee-lid solution with another barrier complements the portfolio with a cost-effective and scalable alternative to traditional single-use plastic lids, reducing the environmental impact of the beverages industry, with more than a hundred billion lids being consumed each year. These achievements collectively allow PulPac and its partner network to now offer production warranties within the highway program.

Sanna Fager elaborates: "Offering our customers a wider range of sustainable packaging solutions is a fantastic accomplishment. But to us, the expanded product portfolio with more barrier solutions shows PulPac's commitment to innovation and efficiency and the continued development of the technology and production line." And in conclusion, states, "We are confident that the products' performance, scalability, and environmental benefits will be game changers for our licensees and the packaging industry. Because this is what consumers want and what the planet needs.

Between May 4th–10th, PulPac showcases its technology at Interpack 2023 in Düsseldorf and invites customers to visit the home of Dry Molded Fiber at Stand 11D12 to learn more about packaging solutions available for licensing. Proven production lines with warranties are available from partners to fuel licensees' sustainability journey.

About PulPac
PulPac provides the packaging industry with groundbreaking manufacturing technology for making economical, high-performance fiber-based packaging and single-use products. By pioneering the technology of cellulose molding, PulPac enables its customers to replace single-use plastics with sustainable and cost-competitive natural fiber alternatives globally. For additional information about PulPac, please visit www.pulpac.com or follow us on social media.

Dry Molded Fiber
The Dry Molded Fiber process, invented and internationally patented by PulPac, is a manufacturing technology designed for the emerging circular economy.  By leveraging globally available, affordable, and renewable commodity cellulose fiber, Dry Molded Fiber technology allows for producing high-performance fiber-based packaging with highly competitive unit economics. Dry Molded Fiber also saves significant amounts of valuable water resources and energy, resulting in up to 80% lower CO2 footprint than alternatives.  Dry Molded Fiber processing is up to ten times as efficient as conventional fiber molding processing, first used over 100 years ago.

Wednesday, 10 May 2023 10:37

Taking steps early

The benefits of preventative heat transfer fluid maintenance

In manufacturing facilities, proactive maintenance is vital to productivity ─ it can reduce the risk of downtime, reduce waste and improve efficiency. Condition monitoring and preventative maintenance is particularly important when working with thermal fluids as manufacturers must maintain production, protect staff and remain compliant with regulations. Here Clive Jones, managing director of thermal fluid specialist Global Heat Transfer, explains how proactive thermal fluid management is the key to safe and efficient operations.

Thermal oils can be heated to very high temperatures for extended periods during operations, which will, over time, cause the fluid to degrade — the rate of this process will accelerate if the fluid is not properly maintained.

Early intervention

Once a thermal fluid enters the system engineers are unable to visually monitor its condition and manufacturers will only be alerted to the condition of the fluid once it has degraded to an extent where it impacts production — for example, food cooks inconsistently or chemicals will not blend. At this stage it is often too late, and manufacturers must cease production to solve the problem and prevent damage, which can be time consuming and costly.

Effective thermal oil maintenance can ensure regulatory compliance, while reducing the risk of costly downtime and the risks associated with explosive atmospheres. By regularly monitoring the fluid and system as part of a preventative maintenance programme, engineers can gain better visibility over operations and intervene earlier.

Specialists should regularly sample fluid when the system is hot, closed and circulating to gain an accurate representation of what is happening inside the system. A heat transfer fluid specialist can provide an analysis of the sample that represents the fluid’s condition from which manufacturers can take action and conduct any maintenance required.

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System monitoring

The by-products of fluid degradation will impact the condition of the thermal fluid system, so proactive system maintenance is as important as fluid maintenance. Conducting regular system walk-rounds enables engineers to detect system issues before they impact production. During the inspection, engineers can monitor gauges to understand what is happening inside the system and look out for shaking pipes or slow production areas. Early intervention to solve these problems, by proactively cleaning, fixing or replacing parts, can increase uptime, reduce energy usage and lower maintenance costs. 

Over time, parts of a heat transfer system will begin to wear, reducing overall efficiency. As well as concentrating on proactively maintaining core components of the system, manufacturers can prepare for when that part breaks down. Keeping critical spares on site, such as pump cartridges, parts for the heater or burner and spare fluid for topping up the system, can be integral to system management.

Around the facility

Just like fluid and system maintenance can improve productivity, making changes around the facility can also positively impact operations. In particular, environmental conditions, such as temperature or humidity, can affect how a heat transfer fluid system operates. Temperature control is important in processes that require indirect heat transfer as the operating temperature of fluid will impact product quality, for instance products may burn if overheated.

When controlling the temperature of the fluid and system, manufacturers must also consider how the heating process will impact the entire facility. If the system, or other machines in the facility, exceed their intended operating temperatures it can lead to equipment failure — electronic panels, for instance, can begin to fail once they exceed 40 degrees Celsius. Installing insulation across the system pipework enables engineers to better regulate temperature. Non-porous insulation, such as blown glass, works well in these applications because if the fluid leaks, the insulation will not absorb the fluid, reducing the risk of fire.

To comply with industry regulations such as The Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) of 2002 and UKEX (formally the Explosive Atmosphere Directive (ATEX 137)) in the UK, manufacturers using heat transfer fluids must take proactive steps to assess potential risks and implement measures to eliminate them as much as possible. Thermal fluid is classed as a dangerous substance, but when monitored routinely and proactively managed, it will give great service for many years which is safer, more sustainable and financially viable for manufacturers.

For more advice on effective thermal fluid and system maintenance, contact www.globalhtf.com/contact/.

About Global Heat Transfer: Global Heat Transfer is a thermal fluid specialist, providing heat transfer engineering assistance and thermal fluid supplies. Services offered include sampling and analysis, 24-hour delivery of premium quality thermal fluids, system drain down / cleaning / waste management, planned maintenance programs and a broad portfolio of affiliated system design and installation services. It is part of the Global Group of companies.

Sustainability is also a major challenge in the food and packaging industry. Plastic packaging is being replaced by organic-based and biodegradable materials, but it must still fulfill high functional requirements. For example, both the product and the packaging must be safely protected from the migration of gas and moisture.

A team of researchers at the University of Hohenheim has developed a new coating system that is both water-impermeable, heat-resistant, and mechanically durable as well as being suitable for consumption, and biodegradable at the same time.

This innovative and universally versatile protective layer was originally developed for use in foodstuffs as a heat-resistant barrier to moisture. So-called “crumbsticks” were created as part of a product development competition.  These are chicken drumsticks with an edible bone made from crispy baked bread sticks. A softening of the two components, which both have a different moisture content, was prevented using the described coating system, which was developed especially for this application.

In the further course of the research, however, additional application possibilities became apparent, especially in fields such as sustainable, organic-based packaging systems. In this case, the coating system is sprayed on and, together with an organic-based carrier material, produces a water-resistant and gas-resistant package.

So-called “crumbsticks” were created as part of a product development competition.So-called “crumbsticks” were created as part of a product development competition.

The scientists at Hohenheim used oleogels in the development of this consumable protective layer. These are fats that are structured using certain gelling agents. The use of some of these is already established in the food sector, for example in the substitution of animal fats and palm oil. What is new, however, is their use as heat-resistant coating to prevent the migration of water within a food product or from a food product into the packaging material.

Existing production processes, mainly from packaging & polymer technology, can be used to create oleogels. The layer of coating can be applied either by glazing, laminating, coating, or spraying and is suitable for food as well as the food packaging field or convenience food packaging. Applications in the pet food sector are also conceivable.

The innovative material can be used in the food sector to separate components with different characteristics. Many processed foods are multi-component systems which are defined by different properties. These include many snack and convenience food products, which often have a dry and a moist (creamy) component. During the production and storage of these products, care must be taken to ensure that moisture from one ingredient is not absorbed into the dry areas of the product. This can be prevented using the protective layer made from oleogel. Even during production processes such as baking or frying, the characteristics of the individual components of the food are retained.

Another application for this coating material is the animal feed sector. Here, too, numerous possible applications are conceivable, such as coating the packaging to protect against moisture, or also separating individual components of the feed.

This new coating exhibits several properties, the combination of which has not been possible before: It is water-resistant, heat-resistant, and mechanically durable while still being edible. By changing the composition or including additives (such as flavorings or colorants), the oleogel layer can be adapted to the specific application. The composition of the oleogel is purely plant-based due to the use of vegetable oils and ethyl cellulose.

The EP patent applications (EP 21207193.0) are pending. Technologie-Lizenz-Büro (TLB) GmbH supports the University of Hohenheim and its scientists in patenting and marketing its current innovation. TLB has been commissioned with the exploitation of this pioneering technology and offers companies possibilities to cooperate and license the patents.

For more detailed information, please contact Innovation Manager Dr. Dirk Windisch (This email address is being protected from spambots. You need JavaScript enabled to view it.)

Watson-Marlow Fluid Technology Solutions (WMFTS) creates powerful and precise pumps that are ideal for applications in the over-the-counter pharmaceuticals and nutraceuticals market. Over-the-counter pharmaceuticals and nutraceuticals demand utmost accuracy and safety throughout the production process. With comprehensively validated performance and convenient clean-in-place maintenance, the highly controlled and hygienic flow of WMFTS pumps help achieve the rigorous quality required for these specialised products.

The MasoSine Certa Sine® sinusoidal pump is certified up to EHEDG Type EL Aseptic Class I standards, ensuring a clean transfer of products such as suppositories and oils. The pump also handles viscosity remarkably well. In fact, it is the best NIPR/NPSHR product in the market. This helps to transfer products such as gels, ointments, and creams while reducing the risk of cavitation. And with one shaft, one rotor, one seal, and no timing gears, the pump ultimately accomplishes a lower total cost of ownership than lobe pumps.

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For products like cough syrup, Watson-Marlow and Bredel peristaltic pumps provide gentle handling and dependability. These FDA compliant pumps perform metering with pinpoint accuracy, providing perfect dosing to ensure the consistency of the end product. These peristaltic pumps also provide unique benefits for pharmaceuticals and nutraceuticals, such as vitamins, supplements, pills, and fish oils. These pumps reduce waste and cut costs by delivering fluids with extreme accuracy. The complete closure of the tube when it is squeezed also isolates the fluid, eliminating the risk of cross contamination.

Products such as over-the-counter pharmaceuticals and nutraceuticals play a vital role in people’s health. And so, they deserve the most powerful and precise pump the market has to offer. For more information about the diverse range of pumps that WMFTS delivers, visit https://www.wmfts.com/en-us/masosine/sinusoidal-pumps/certa-plus-process-pump/.

About Watson-Marlow Fluid Technology Solutions

Watson-Marlow Fluid Technology Solutions is an award-winning, global leader in fluid management technology and for over 60 years has engineered components and systems for customers in the food processing and handling, pharmaceutical and industrial markets. The company is part of Spirax-Sarco Engineering plc, a FTSE 100 company. Learn more at www.wmfts.com

There’s been a lot of talk in the world of safety about the need for real-time data with gas detection systems. Although most will agree that real-time data benefits safety programs by providing information that leads to better decision-making, some may wonder if real-time data is as crucial as they’ve heard.

The short answer is yes, and here’s why.

A properly calibrated and bump-tested gas detector is a powerful personal protective device. By itself, however, it’s simply not enough to help ensure the highest level of safety.

That’s where a connected work platform comes into play.

A connected work platform combines real-time data, connected PPE/gas detection wearables, and advanced software solutions, so you can have the best possible visibility across these areas of concern:

  • Workers
  • Worksites
  • Workflows

In fact, connectivity enables the kind of visibility that can lead to a stronger safety program and improved safety outcomes.

Even better? A strategic connected worker-worksite-workflow platform helps simplify safety, curb risk, and boost productivity all at the same time. Plus, it sets you up for a scalable and adaptable safety program for today – and tomorrow.

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Consider these three reasons why real-time data via a connected platform is a must for worker and worksite safety:

In fact, connectivity enables the kind of visibility that can lead to a stronger safety program and improved safety outcomes.

Even better? A strategic connected worker-worksite-workflow platform helps simplify safety, curb risk, and boost productivity all at the same time. Plus, it sets you up for a scalable and adaptable safety program for today – and tomorrow.

Consider these three reasons why real-time data via a connected platform is a must for worker and worksite safety:

1. Real-time data enables real-time visibility for safety teams.

By their very nature, remote workforces leave safety managers disconnected from what’s happening on the job. So, what’s a disconnected and physically distant safety manager to do in the event of an unsafe incident, especially when every second counts?

Here’s what they can do. They can ensure that lone workers are not alone, thanks to the visibility provided by a connected platform. If workers, worksites, and workflows are not connected, there’s likely going to be too much lag time between incident and information – lag time that’s costly to both worker safety and infrastructure.

With connectivity-enabled real-time data, safety managers can have continuous situational awareness. That means seeing the state of workers and monitoring their safety behaviours in the field. It means you’ll get gas exposure alerts, man-down alarms, panic button presses, and device concern warnings in real-time so you can act as swiftly as possible. Plus, it means simplifying compliance and improving productivity to help reduce risk and costly downtime.

Real-time data gives safety managers real-time visibility and awareness into what’s happening, so they can respond to incidents – and help improve safety of workers, worksites, and workflows – much faster.

The key to leveraging critical real-time data is having your hardware or gas detection devices connected to both the right software and to the cloud through a seamlessly integrated solution. While the device does its job of collecting data, the software does its job of empowering safety managers with information and insights that let you drive a more proactive safety culture. Even better is that this creates a more unified and streamlined workflow. No relying on cumbersome file transfers and downloads. No more time spent on the arduous and complicated task of piecing together information for incident reporting.

A comprehensive hardware-plus-software connected gas detection solution gives the entire safety team a single, go-to place (accessible anytime, anywhere with an internet connection) for the data and support required to support operational efficiency and enhanced worker and worksite safety.

2. Real-time data helps improve operational efficiencies.

Gas detector check-ins and check-outs can be extremely slow and inefficient. They are, however, crucial to ensuring that workers use their PPE devices correctly – and that the devices are properly returned to the fleet. Based on our work with clients across a variety of industries around the world, MSA estimates that roughly 20% of gas detection devices never make it back to the fleet. Not only are the devices lost, but in a disconnected program, the data is also gone forever.

Thanks to a connected program, safety managers can assign a device to a worker, enabling real-time, worker-specific data. That, in turn, can lead to significant operational efficiencies, including:

  • Automated check-in and check-out for daily, project-specific, and long-term use
  • Increased worker accountability for the device and its whereabouts
  • Faster understanding of what’s happening with the worker, including the type and level of exposure
  • Easier identification of noncompliant workers (those that ignore alarms and remain in a hazardous environment) so they can be trained or re-trained on proper safety procedures and protocols

3. Real-time data better safeguards lone workers for better peace of mind.

There are more than 50 million lone workers in the U.S., Canada, and Europe, most of whom are found in the oil & gas, telecommunications, utilities, construction, and industrial industries.1 It’s no secret to lone workers or their safety managers that their working conditions are uniquely and inherently fraught with a variety of potential hazards, including accidents, emergencies, and illnesses that require trained, capable, and properly equipped workers to do their jobs under such conditions.2

Connected workers, on the other hand, can be better kept free from harm. Compliance, fleet manager, or live monitoring services extend visibility, helping ensure that critical data points are delivered in real-time from on-site workers to off-site safety managers. Not only does this help protect the lone worker from gas exposures, but it also connects them to real and tangible help when needed.

As any lone worker can attest, working alone is not the same as being alone. Thanks to in-the-moment monitoring and real-time data, lone workers can have the peace of mind that comes from knowing their safety team has their back whenever and wherever they’re on the job.

What safety teams can do

A connected work platform can seamlessly integrate connected workers, connected workflows, and connected worksites to help you build and maintain a flexible and proactive safety program that only gets better with time. Now that you know the benefits of a connected gas detection program, the next step is to take a deeper dive into understanding where you are on your connected journey and identifying the right partner to help support your organisation’s safety, productivity, and compliance goals.

Learn more about connected work, real-time data, and more: https://gb.msasafety.com/connected-work

References

1 https://www.ishn.com/articles/104413-how-to-protect-remote-lone-workers

2 https://www.hsa.ie/eng/Topics/Hazards/Lone_Workers/

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