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ERIKS Know+How Issue 18 - Food and Beverage

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Issue 18 of ERIKS Know+How , the leading magazine for Maintenance Engineers. This edition is focused on the Food and Beverage industry. …

Issue 18 of ERIKS Know+How , the leading magazine for Maintenance Engineers. This edition is focused on the Food and Beverage industry.
Includes articles from NSK, KSB, SKF, Rocol and Festo to name but a few.

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  • 1. What’s eating you? 10 page focus on the problems and possible solutions facing the food and drinks industry p12 A taste for efficiency Bigger portfolios, lower costs p10 ‘Wire to Water’ efficiency A new whole-system efficiency approach p22 Step this way 5 steps to a smarter storeroom p24 Born or made? What’s eating you? RAGE •FO CUS ON • FO O D & BEV E RAGE #* The leading magazine for mainTenance engineers from eriKs www.eriks.co.uk/knowhow ISSUE 18 The engineers who’ll inherit the future p6
  • 2. ADVERT FENNER GEAR MOTORS EXCELLENT COMFORT AND PROTECTION RX® Disposable Masks are an essential requirement when working in atmospheres where harmful gases, vapours, smoke or mist particles are present. Offering a high level of protection and constructed using non-allergenic materials, RX® Disposable Masks are lightweight and ergonomically shaped for a comfortable fit. Manufactured to the highest standards, our range of masks include adjustable nose and head straps to ensure a good, air-tight seal, an exhalation valve for easier breathing and conform to the latest European standards. Feel the difference. Order your RX® disposable masks today. Call 0800 006 6000 or visit www.eriks.co.uk RX® Disposable Masks offer a high level of protection against dust particles, mist and fumes - now you can breathe easy! Take a breather. Safety ProductS RX® DIsPOsAbLE MAsks RX® FLAT-FOLD DIsPOsAbLE MAsk RX® PRE-FORMED (CuPPED) DIsPOsAbLE MAsk RX® PRE-FORMED (CuPPED) AND REINFORCED DIsPOsAbLE MAsk
  • 3. 3 Contents Welcome To KnoW+hoW… Bringing you the latest industry stories from around the world, plus technology updates, features and comment. Our industry focus this issue is the food and beverage sector, which, according to a recent survey, must focus closely on reducing waste to please its customer-base and strengthen consumer confidence. As our editorial discusses, the need to reduce waste is part of a wider awareness among the public that sustainability in all possible forms is the future. Practical solutions for the food and beverage industry discussed this month includes a piece on rocol (foodlube), the first organisation in UK to add metal detectable actuators and caps to aerosol spray cans. meanwhile our Planet+ feature discusses the benefits of thermographic technology for the food and beverage industry. also this month we look at energy saving, specifically drive system energy losses and preventative action. There’s a KsB pump article on cleaning in Place (ciP), discussing the need for all parts to allow unimpeded flow-through and covering products that meet these criteria, while sKf explains how to keep machinery operational in extreme temperatures. if you have any issues you wish to raise or comments to make you can email the editor at: knowhoweditor@eriks.co.uk, not forgetting Know+how’s own website: www.eriks.co.uk/KnowHow where you can register for your own personal copy and make enquiries about something you have read or contact one of the contributors. I look forward to hearing from you. Alan Whetstone Managing Director, Editor in Chief Published by eriKs UK, amber Way, halesowen, West midlands, B62 8Wg UNREGISTERED NEW QR CoDE ACCESS To make it easier to get all the latest industry news straight to your mobile device or smartphone, simply scan the Qr codes throughout. LatESt NEwS 04food and beverage – the top 10 trends for 2014 first pump auditing certification liverpool to become a manufacturing centre of excellence 4d printing technology goes composite london’s Tube network transports heat into homes IN-DEpth 06Where are tomorrow’s engineers? tEchNoLogy UpDatE 08eriKs acquires leader global Technologies eriKs pump repairs make £4k annual saving at UK auto plant eriKs enhances customer service with new marine appointment new sealed sKf single row angular contact ball bearings now available Top 10 Tips for hose assembly pLaNEt pLUS 10The recipe for efficiency FocUS oN FooD & BEVERagE 12Waste not want not p12 savings in pints p13 raise a glass to KsB pumps p14 food and beverage processing? it’s meat and drink to sKf p16 foodlUBe® has safety in the can p18 fresh from the festo factory p20 ENERgy SaVINgS 22saving energy from the ‘wire to the water’ BESt pRactIcE 24step away from the problem •FO CUS ON • FO O D & BEV E RAGE
  • 4. Latest news ISSUE 18 www.eriks.co.uk/knowhow4 a recent survey has predicted that cutting waste and building trust will be two of the key food and drink industry trends of 2014. The top 10 predicted trends, from a survey by innova market insights, will be as opposite: The need to build trust has been fuelled by recent food safety scares and scandals, which innova says have crippled consumer confidence. This has no doubt also increased scrutiny on the number one issue – waste. The survey also identified that consumers are now reassessing their needs and going ‘back to basics’ by rediscovering the simple pleasures of home cooking, while the rapid rise of social media platforms is likely to propel more small-scale innovators with high quality produce into the limelight. Food and beverage – the top 10 trends for 2014 First pump auditing certification charlotte marsh has become the first ERIKS employee to receive the new certified Pump system auditor (cPsa) qualification from the British Pump manufacturers association limited. To achieve her accreditation – designed to be a universally recognised and respected industry standard for engineers who assess the performance of pumping systems – charlotte attended five days of courses. Three days were spent on a pumping system requirements and analysis training course, followed by an exam. one day covered energy assessment of a pumping system to either asme ea2-2009 or iso 14414, and a further day was devoted to a pump system optimisation course. lastly, charlotte carried out a pump system audit and produced an audit report, both in accordance with the relevant industry standards. The report was then reviewed by an expert panel. The new certification scheme aims to improve levels of professionalism within the pumping sector, and is open only to competent engineers who can demonstrate active involvement in the industry. cPsa engineers must be re-assessed every three years to maintain their certification. The British Pump manufacturers association limited believes that the new certification will help engineers become more effective in their role, and show their employer’s industry leadership. 1. Waste not want not: cutting food waste 2. You can trust us: improving consumer trust 3. Simpler pleasures: back to basic trends towards simpler food 4. Look out for the small guy: small-scale innovators rise to the challenge 5. Health is more holistic: a more holistic approach in providing nutritious food and beverage solutions to consumers 6. ‘New’ superfoods 7. Rise of the hybrid 8. The Protein Horizon 9. New stealth strategies 10. Alternative alternatives
  • 5. Latest news 5 liverpool is to develop a select range of techniques to become a manufacturing centre of excellence by 2020. The plan is being mapped out by the liverpool city region local enterprise Partnership (leP) in consultation with number of advanced manufacturing partners in the locality and will focus on the technologies of lightweighting, non-invasive monitoring, shale gas exploration and sustainable energy. The initiative follows a current school of thought that, in the global economy, the best way to build manufacturing is to focus on, and invest in, existing strengths and establish centres of excellence to push forward innovation. in its report, 'making it: advanced manufacturing in liverpool city region to 2020', the leP states: "a manufacturing environment with four or five clusters of excellence – with one frontier industry – could provide a framework to produce high value goods and services”. an innovative heat recovery scheme will provide warmth for local homes by channelling waste heat from london Underground tunnels. as anyone who has ever travelled during rush-hour knows, the london Underground system generates large amounts of heat. To put this energy to good use (and relieve a few passengers) warmth will be captured from a northern line vent and piped into the heat network. The project is a partnership between islington council, the mayor of london Boris Johnson, UK Power networks and Transport for london. The mayor of london’s senior advisor on environment and energy matthew Pencharz said: "By supporting locally-sourced energy and heat networks, which can reduce bills and lower carbon emissions, we cannot only save money but also drive innovation, jobs and growth in this burgeoning sector." a team from the University of colorado has developed and tested a method of 4d printing that could advance the use of adaptive, composite materials in manufacturing and biomedical applications. The concept allows materials to self-assemble into 3d structures by incorporating shape memory polymer fibres into composite materials that can later be changed to take on a new shape. “in this work, the initial configuration is created by 3d printing, and then the programmed action of the shape memory fibres creates time dependence of the configuration – the 4d aspect,” explained researcher martin dunn, from the singapore University of Technology and design. it is predicted that developments in 3d and now 4d printing technology will help create reversible or tuneable 3d surfaces and solids in engineering, such as the composite shells of complex shapes used in automobiles, aircraft and antennae. Liverpool to become a manufacturing centre of excellence 4D printing technology goes composite London’s Tube network transports heat into homes
  • 6. In-depth ISSUE 18 www.eriks.co.uk/knowhow6 recent media interest began with a double-whammy of attention-grabbing soundbites. chief scientific advisor at the department for Business, innovations and skills – Professor John Perkins – warned that the UK’s economic recovery could be ‘constrained’ by a lack of engineering skills. at the same time, Business secretary Vince cable claimed that a relatively low number of young people were choosing to study maths and science, in which ‘engineers must have a strong foundation’. With an acknowledged ageing workforce, meaning vital skills and experience are leaving the industry, it certainly looks grim for engineering. and yet there are happier headlines, successful initiatives, and plenty of bright young would-be engineers slipping into newly acquired overalls. The best of the best accredited as a Top employer by the crf institute in 2013, ERIKS takes its responsibilities for the future of the industry very seriously. Which is why the company runs not only an apprenticeship scheme but also a graduate scheme. and their success is being recognised beyond the business itself. While the media were focusing on the doom and gloom, two young ERIKS engineers were making headlines of their own, collecting a brace of awards. Jacob Kane – an apprentice with ERIKS chesterfield – was awarded apprentice of the Year by the institute of engineering and Technology, while fellow ERIKS employee liam greveson won the first-ever exceptional achievement award from the electrical apparatus service association (easa). Jacob was fully-funded by ERIKS to study an electrical and mechanical engineering BTec, on the ERIKS apprenticeship scheme. ERIKS takes on 10-15 apprentices across the UK every year for this 3-year scheme, which involves 24 weeks a year, 3 weeks at a time, at loughborough college – one of the UK’s leading universities for engineering and technology. Then in addition, the apprentice undertakes 40 weeks of full-time work in ERIKS’ workshops. liam had spent 7 years with ERIKS before receiving his award from easa. he also began as an apprentice, starting on the shop floor as a Tester/fitter, and is now a condition monitoring engineer. his award from easa was presented to him in Palma, mallorca, and he also visited two easa member companies, including the award sponsor: Karsten moholt as of norway. How managers are made ERIKS’ graduate scheme – known as the ERIKS UK academy – is a brand-new initiative from ERIKS. it will undoubtedly become another important contributor WHERE ARE ToMoRRoW’S ENgiNEERS? IF yoU LIStEN to oNE oF thE goVERNmENt’S aDVISERS – aND INDEED to oNE oF ItS mINIStERS – yoU’D BE FoRgIVEN FoR thINkINg that FRESh BLooD IS SEVERELy LackINg IN thE ENgINEERINg INDUStRy. BUt IF yoU Look BEhIND thE hEaDLINES at SomE oF thE BUSINESSES whIch aRE pLaNNINg FoR thE FUtURE, thEN thE StoRy IS a VERy DIFFERENt oNE.
  • 7. In-depth 7 of new blood to the industry, helping to boost the UK recovery in the short-term, and maintain and strengthen the country’s engineering base in the long-term. The scheme is currently in the recruitment and selection stage for its first year’s intake, but the intention is to take on ten graduates for a comprehensive programme of learning and development across the business UK- wide, covering all divisions of the company. The scheme lasts for two years and offers three programmes, each one geared to graduates in a different discipline: either electro-mechanical engineering, general engineering, or commercial Business and management. ERIKS’ learning and development department will put together a full training and development scheme for each graduate, including a personal development programme, and all the graduates will be mentored by senior management and the hr director. There will also be regular performance reviews. Planning for the future The ultimate aim of both the apprentice and graduate schemes is to recruit quality candidates for ERIKS. successful apprentices will go on to be employed in hands-on engineering roles for the company, but can also move into management positions. graduates, meanwhile, are specifically recruited for eventual management posts. (see box-out). so ERIKS’ drive to develop the engineers of the future is not entirely altruistic. But why would potential employees want to work for ERIKS? as europe’s leading industrial services partner, the company offers the potential of a rewarding career with a secure future. But it’s more than that. The Top employer accreditation from the crf institute – an organisation that identifies the top performers in human resources – proves that ERIKS is committed to its employees and their care and development. The accolade recognised an outstanding level of employee care by ERIKS across several categories, citing the company’s exceptionally high standards in categories such as Working conditions, Training and development, career development and culture management. By training, developing and employing the best and brightest talent of today, ERIKS aims to create the best engineers of the future – which will, of course, be good for ERIKS. But it will also be good for all of us within the industry, and ultimately for everyone who will benefit from a prosperous Uk. Having joined a family business – subsequently taken over by ERIKS – straight from University, I am in my 30th year with the company. I started as a Graduate Trainee in the Commercial Department, managing National Agreements and customer entertainment facilities, assisting in importing spare parts from Germany and the USA, and acting as Quality Manager. A secondment as a Sales Representative for a Service Centre was followed by a period as Service Centre Manager. At 25 I became Commercial and Contracts Manager on the Board of Management, then managed our German distribution arm, subsequently returning as UK National Contracts Manager, becoming a Director in 1995. When the business was acquired by ERIKS I was appointed European Key Accounts Director, before returning to my old role in 2010. I am delighted to be part of a company with very ambitious owners who can take a longer-term view. David Arbuthnott Corporate Key Accounts Director, ERIKS UK
  • 8. Technology update 8 ISSUE 18 www.eriks.co.uk/knowhow ERIKS acquires Leader global Technologies ERIKS hAs Acquired All of The commerciAl AcTiviTies of leAder GloBAl TechnoloGies (leAder), A leAdinG mAnufAcTurer And provider of spirAl wound And meTAl GAskeTs for A vArieTy of indusTriAl ApplicATions worldwide. leAder is heAdquArTered in housTon, TexAs wiTh AddiTionAl operATions in BATon rouGe, lA And ByTčA, slovAkiA. speaking on the acquisition, ERIKS ceo Johan sleebus said, “The acquisition of leader brings ERIKS a well-known brand in a key product category. The company manufactures high-quality products for use in end markets that are at the core of ERIKS’ global technical services strategy.” leader has a well-established business model of providing ‘engineered sealing solutions through Partnered distribution’. The company will continue to implement this channel strategy on a global basis. The leader Us operations will become a part of the ERIKS north america business while the Bytča, slovakia manufacturing facility will become part of the ERIKS european operations. ERIKS pump repairs make £4k annual saving at UK auto plant ERIKS hAs cArried ouT A pump repAir plAn for A mAjor uk AuTomoTive mAnufAcTurer ThAT hAs resulTed in An AnnuAl enerGy sAvinG of ApproximATely £4,000. The plAn, which included pump repAirs conducTed wiTh henkel, hAs Also Achieved A co2 sAvinG of 28 Tonnes in The firsT yeAr. Work began when ERIKS evaluated the efficiency of one of the automotive company’s pumps. The pump in question was a 22kW elPo, which handles process water for a metalwork pre-treatment process prior to body coating. The result of the test was that the pump was found to be under- performing by at least 30% against the manufacturer’s original test data. an estimated energy reduction of £3,936 was calculated for the first year alone (calculated at £0.08/kWh at 12 hours per day with an 80% load). it was therefore clear that the cost of the repair, which amounted to £5,542, would soon be recovered and that substantial savings were to follow. over a five-year period, this accrues to a five-year energy saving amounting to £19,680. ERIKS enhances customer service with new Marine appointment ERIKS hAs enhAnced iTs offer To mArine cusTomers wiTh The AppoinTmenT of simon hemper, mArine Business developmenT mAnAGer. simon’s depTh of experience in The mArine indusTry will Be exTremely vAluABle for All cusTomers involved in specifyinG mArine soluTions To enhAnce efficiency And performAnce. simon has joined ERIKS from aderco fuel treatment, and has been appointed to develop and build on ERIKS marine offer in response to growing demand. With over 30 years’ experience in the marine industry, simon has an outstanding track record of achievements, including winning a contract for equipment supply to four P&o new build cruise ships worth close to £2million. ERIKS marine services include overhaul and rewinding of generators and motors, condition monitoring, vibration analysis, thermographics, dielectric loss analysis, and on-board pump and gearbox repairs.
  • 9. Technology update 9 New sealed SKF single row angular contact ball bearings now available skf hAs Announced ThAT iT hAs developed A new seAled sinGle row AnGulAr conTAcT BAll BeArinG suiTABle for ApplicATions in mAny indusTries, rAnGinG from pumps And compressors To GeArBoxes, elevATors And elecTric moTors. The new bearing features two non-contact steel reinforced nBr (nitrile Butadiene rubber) seals, and a high performance, long lasting polyurea (gXn) grease as standard. The non-contact seal lip design forms an extremely narrow gap between the seal lip and its counterface on the bearing inner ring to exclude contaminants and retain grease, even in applications with vertical shafts. and because they are non-contacting, the seals do not generate frictional heat, which enables the bearings to operate at the same high speeds as open bearings. cooler operating temperatures also extend the service life of the lubricant. in comparison tests, sealed sKf single row angular contact ball bearings operated with 30% lower peak temperatures and 20% lower steady-state temperatures than same-size bearings with contact seals (values based on °c). sealed sKf single row angular contact ball bearings are dimensionally interchangeable with open bearings and have the same high load carrying capability. 1. Respect your hoses and fittings. The incorrect selection of hose type could lead to catastrophic failure and injury, as well as production down time. 2. Be aware of the dangers. consider operational changes such as increased temperature, pressure, or new chemicals, and how they will affect all the process items such as the hoses. 3. consider newly enhanced components. advances in technology have brought engineers the option to specify bespoke industrial hose assemblies that are lighter and stronger, and can meet the needs of many different applications. 4. match the fitting to the hose. only by making the correct specification to match the hose itself can engineers maintain the productivity and quality of the hose output. 5. Specify correctly for low pressure. careful specification and installation is required here, as misalignment or over-tightening may cause leaks. 6. Specify correctly for high pressure. in higher pressure applications, swaged or crimped connections or lmc clamp fittings offer an excellent degree of security, giving leak-free connections. 7. allow time for manufacture. Whilst it is possible to manufacture, test and ship a hose the same day, stock allowing, consideration should be given to holding spares of commonly used hoses. 8. consider clamp fittings. There are now some highly effective safety clamps on the market in aluminium, brass and stainless steel. 9. operate a consistent maintenance programme. The need to protect productivity, safety and profitability is great in all applications but the issue can be critical in certain industries. 10. consider a hose testing service. ERIKS hose Technology offer a cost-effective hose testing service, with hose assemblies being visually inspected, pressure tested and checked internally with a ccTV camera. for hose AssemBlyToP 10 TiPS10 T For more detailed information scan this QR code
  • 10. 10 ISSUE 18 www.eriks.co.uk/knowhow You and the condition monitoring tools, for example, used to their full capability, can significantly improve efficiency. a thermal imaging camera is capable of everything from detecting a damaged link in a drive chain generating extra friction and heat, to evaluating the effectiveness of doors and seals. Thermography plays a vital role in monitoring product quality in food production because of the wide variety of temperature-controlled operations involved. as a non-contact method for monitoring and controlling ‘temperature critical’ products, it is invaluable in the control of cooking or sterilisation processes. it is also becoming increasingly important throughout the distribution chain for perishable food materials, and for temperature control of frozen and fresh food to help maintain product quality and reduce safety risks. Heat casts light Thermal imaging cameras measure infrared radiation, then represent temperatures with colours on an lcd monitor. a thermographic survey by an experienced and certified operator is a swift and inexpensive condition monitoring option, which can save thousands. a recent thermal imaging survey by ERIKS at the coors brewery in Burton cost less than £1,000, yet highlighted potential savings of around £60,000 per annum from a relatively modest investment in repair work. optical gas imaging cameras also use thermographic technology, to detect leaks – safely scanning thousands of components per shift, with zero downtime. Because gases are opaque in the infrared wavelength, the cameras can ‘see’ the leak, and a trained technician with a high-end camera can detect more than 20 different toxic, explosive and flammable gases – often including those normally difficult to detect, such as carbon monoxide. Efficiency in store sharper management of maintenance, repair and operations (mro) procurement and stores activity can also make significant improvements in plant efficiency and economy. accessible, well-organised stores keep the factory floor running smoothly, because engineers can quickly find the equipment they need. a well-organised store is also easier to manage because stock replacement requirements are more visible. ERIKS recently helped a major food manufacturer reduce mro costs while increasing productivity. Their paper-based stores management system was replaced with a paperless software solution, and barcoding enabled the 7,500 stock items to be accurately traced. The streamlined system also capitalised on the data gathered to deliver a flow of highly useful management information. The above examples highlight some of the ways plant engineers can reduce total cost of ownership. By partnering with an experienced solutions provider with expertise in a range of technologies, food and beverage manufacturers can maintain product quality and variety in this challenging economic climate, while still managing costs. cUStomERS oF FooD aND BEVERagE compaNIES aRE INcREaSINgLy SEEkINg ShoRtER tURNaRoUND tImES FoR EVER moRE compLEx pRoDUct poRtFoLIoS, to RESpoND to VaRyINg maRkEt DEmaNDS. So maNUFactURERS NEED aLL thE tooLS thEy caN gEt, to maINtaIN pRoDUctIoN EFFIcIENcy aND maNagE coStS. THE RECiPE FoR EFFiCiENCY thermographic survey by an experienced and certified operator is a swift and inexpensive condition monitoring option, which can save thousands. thermographic survey by an experienced and certified operator is a swift and inexpensive condition monitoring option, which can save thousands. Dave manning-ohren condition monitoring manager, eriks
  • 11. Motivair is the UK’s largest independent compressed air management company, offering a wide range of products and services for all the major brands of compressor: • Planned maintenance and service plans • 24/7 breakdown support • Compressed air equipment, parts and accessories • Consultancy, energy savings and lower costs • ERIKS approved supplier Motivair ensures continuous compressed air supply No matter what brand of compressor One call for all your compressed air needs.
  • 12. Focus on Food and Beverage 12 ISSUE 18 www.eriks.co.uk/knowhow in our news pages this issue we report on a recent survey that has predicted, cutting waste and building trust, will be two of the key food and drink industry trends of 2014. The phrase that tops the list of ten predicted trends by innova market insights is ‘Waste not Want not’, reflecting manufacturers’ efforts to reduce food loss or waste. “food loss during production and food waste, at the retailer and consumer end of the food-supply chain, will be heavily scrutinised,” forecast innova, while ingredients derived from the waste stream were also said to hold big potential. While the need to build trust has been fuelled by recent food safety scares and scandals that have damaged consumer confidence, the need to reduce waste is no doubt part of a wider awareness among the public that sustainability in all possible forms is the future. The food and beverage manufacturing industry must now capitalise on new technology to increase operational efficiency and prevent wasted product. for example, the potential to gather and share information that is currently offered by barcodes and sensors can be more fully exploited by the engineering industry, particularly in the way we manage our supplies. efficiency has to improve and this will also accelerate the need for more responsible operations. The need to be more efficient as a means of increasing profits goes hand-in-hand with the growing change in the attitudes of both engineering companies and their customers towards conducting more ethical operations. We are moving towards a more responsible industry, where specialists and innovators are prized more highly than ever before. The food and soft drinks industry is the UK’s largest manufacturing sector and has remained strong in the difficult economic conditions that prevail, even as commodity prices have climbed. one reason for this is that, whatever the economic climate, we tend to go on eating and drinking product of one kind or another. however, it may also have something to do with good installation and maintenance. food processing and packaging companies understand more than most the vital need to protect production and optimise productivity, and ensure reliable predictive and preventative machine maintenance programmes to avoid delayed deliveries, wasted produce and damaged reputations. The continued success of the food and beverage industry will therefore rely heavily on both science and technology and, of course, the ability to further increase efficiency and product quality – all the while adhering to stringent sustainability guidelines. food and drink producers are in the fortunate position of being able to take advantage of ongoing developments in processing technology and the need to continually enhance the reliability of processes cannot be underestimated. paUL LyNch LookS at tRENDS IN thE FooD aND BEVERagE INDUStRy aND why EFFIcIENcy LookS SEt to BE thE kEy DRIVER whEN It comES to cUStomER SatISFactIoN aND pRotEctINg pRoFItaBILIty. paul Lynch customer service director - integrated solutions, ericks
  • 13. Focus on Food and Beverage 13 thE DowNSIDE oF FREqUENt BEaRINg FaILURE IS thE tImE, tRoUBLE aND ExpENSE oF DowNtImE, LoSt pRoDUctIoN aND REpLacEmENt. thE UpSIDE IS that thE moRE oFtEN It happENS, thE SooNER It wILL BE oBVIoUS that thE FaILED BEaRINg IS a Symptom, Not a caUSE, aND that It’S tImE to Look DEEpER INto thE pRoBLEm. for engineers at a milk processing plant the realisation came quickly, as the bearing on one of its conveyors was failing every 10 weeks, leading to downtime of three hours every time it happened. so they called in nsK to solve the problem sooner rather than later. A tough job… life for the bearing – and for the maintenance engineer – was made harder by the bearing’s inaccessible location. This made it difficult to lubricate, which shortened the bearing’s life, and then increased the downtime whenever it needed replacing. so nsK looked for a solution which not only increased the bearing’s service life, but also eliminated the need for lubrication. The answer was life-lube® stainless steel bearing inserts, with molded-oil solid lubricant. These are available in Pillow Block, 2- and 4-bolt flanges and take-up unit housings, with bore sizes from 20mm to 40mm. More life, less maintenance The new bearing brought multiple benefits to the application. not only did it extend bearing life – from 10 weeks to more than 12 months – but it also eliminated the need for lubrication maintenance during its lifetime. in addition, when the bearing finally did require replacement, its design meant there was no need to replace the bearing shaft – unlike with the previous type of bearing. The longer service life was partly due to the PBT thermoplastic resin housing of the new bearing, which is corrosion resistant. The housing also has the added benefit for food and beverage applications that it is paint-free: meaning no chipping or flaking, and no risk of contamination of the process. made from martensitic stainless steel, with nitrile rubber seals, the bearing is also resistant to contamination, making it ideal for operations where process fluid is unavoidable. Milking the savings as well as identifying the cause of the bearing failure – insufficient lubrication due to inaccessibility – and recommending the life-lube® housing and molded-oil insert to resolve it, nsK also provided expert technical support for fitting of the new life-lube® units. The end result of changing the existing bearings for the nsK solution, was significant cost savings for the customer, delivered to their doorstep. EXiSTiNg CoST P.A. NSK SoLUTioN CoST P.A. old bearing design: €140 new bearing design: €136 lab: 2 fitters × 3 hours @ €25/h, 5 × year €750 no maintenance €0 downtime: 3 hours @ €2.055, 2 × year €12,330 no downtime €0 2 x shafts replaced @ €110 each €220 no replacement shafts €0 Total cost €13.440 Total cost €136 kevin Delehanty senior Applications engineer nsk
  • 14. Focus on Food and Beverage 14 ISSUE 18 www.eriks.co.uk/knowhow BEER DoESN’t jUSt NEED hopS, watER aND yEaSt. It aLSo NEEDS RELIaBLE pUmpS at EVERy StagE FRom BREwhoUSE to BottLINg. kSB haS BEEN SUppLyINg thE NEcESSaRy EqUIpmENt SINcE 1871, FoR pRImaRy pRocESSES aND FoR cooLINg, watER tREatmENt, waStE watER tRaNSpoRt aND othER SEcoNDaRy cIRcUItS. dependent upon the yeast viscosity, KsB Vitacast centrifugal or Vitalobe rotary lobe pumps can be used in yeast cellars. however the Vitalobe handles the higher viscosity whilst still handling the shear sensitive product. a gap between rotor housing and bearing bracket protects pump and fluid from excessive heating and prevents lubricant from contaminating the fluid. There is also a choice of mechanical or shaft seal sealing rings – with or without a flushing device – for the shaft passage through the rotor housing of the Vitalobe. Tailored to the application after storage and maturation, the filtration process also use pumps, and KsB offers a range of suitable models from Vitachrom and Vitacast to Vitalobe and Vitastage. finally, the bottle, drum or keg filling station is the most demanding location for hygiene. low inlet pressures and beverage blending systems operating under vacuum conditions add to the challenge the pumps face. such applications call for european hygienic engineering & design group-certified, single-stage centrifugal pumps such as Vitachrom, which offer 13 different sizes and flow rates up to 340m3 /h, so it can be optimally sized to meet requirements. The back pull-out design and stub shaft means that pump and motor each have their own shaft, making these pump sets highly maintenance-friendly. Cheers! Beginning in the brewhouse, processes are sterile so pumps must be manufactured from certified materials that can be cleaned and sterilised in place. cleaning in Place (ciP) requires all parts to allow unimpeded through-flow, with little dead volume, smooth-as- possible surfaces, and gapless, easy-to-clean casings. Pumps must also be fully resistant to cleansing media and high temperatures, with o-rings open and arranged directly toward the product. Back vanes on a semi-open impeller enable good circulation around the mechanical seals. single- or multi-stage etanorm or movitec pumps are used to transport the water to the mash tun, where milled malt is mixed with brewing water and enzymes to produce the wort. The lautering process uses single stage pumps, such as stainless steel etanorm or Vitachrom models. Where the fluid mixture contains gas or solids, the Vitachrom with its open impeller expels residual oxygen and can handle products containing solids without clogging. The wort is initially more viscous, so for smooth handling the pumps must be precisely tailored to suit the operating conditions. it is then boiled in a boil kettle, requiring a powerful pump to circulate the kettle contents eight to ten times an hour throughout the process. Easy on the fluid after cooling, the wort is oxygenated, and the Vitaprime is ideal for handling the gas laden liquid – designed for continuous operation at temperatures up to 140°c and a rated pressure of 10 bar.
  • 15. ADVERT WEG RAiSE A gLASS To KSB PUMPS Motors | Automation | Energy | Transmission & Distribution | Coatings Are you ready for the change? European Directive 2005/32/EC states that from January 2015 all motors with a rated output of 7.5kW – 375kW shall meet the level of IE3 or IE2 when driven by an inverter. At WEG, we offer both IE3 and IE4 efficiency level motors in standard IEC frame sizes. WEG also offer a complete range of VSD’s ensuring that not only can you meet the legislation, but keep both your CO2 emissions and running costs to a minimum. WEG, energy efficiency as a standard not an option. For information on how to make the change, visit www.weg.net/uk
  • 16. 16 ISSUE 18 www.eriks.co.uk/knowhow Focus on Food and Beverage There are some industrial environments which offer the same extremes of temperature found in food and beverage facilities. some may be equally moist, and prone to contamination. some may even have as many washdowns which can degrade equipment and potentially cause lubricant leakage. some may also involve repetitive tasks in hazardous working environments. But there are not many industries where all these factors are combined to make life hard for equipment and its components. But that’s not all the food and beverage industry has on its plate. There are also the pressures that you can blame on the rest of us: the consumers. ever more picky and particular, with ever-changing tastes and preferences, we continually demand new food and beverage sensations, which means manufacturers are continually placing new demands on their equipment and technology, which have a knock-on effect on the machinery and productivity. Then, last but not least, all these pressures have to be addressed while trying to reduce prices, but without cutting corners on meeting strict health, food safety and environmental legislation. so with rising costs for energy and labour, it’s clear the need to optimise equipment reliability and maximise uptime and productivity is greater than ever. From field to fork over the decades, sKf has worked alongside companies from almost every sector of the food and beverage industry, at every stage of production and at every point in the supply chain. from national and multi-national soft drinks producers to major UK bakery companies; from frozen food producers to makers of salads and ready-made sandwiches; from brewers and distillers to confectioners and crisp makers – sKf has worked with them all. and from growers and farmers through to processors, manufacturers and packaging and labelling companies. so naturally sKf know and understand the problems they face, the restrictions and legislation that they have to comply with, and the environments in which they have to work. When the going gets tough… The tough conditions in which the industry operates – which prove such a challenge for all kinds of equipment and manufacturers – have driven sKf to develop new and better bearing solutions for the entire food and beverage production process. sKf has dealt with equipment involved in preparation, heating, cooling, and post- production packaging: from ovens, conveyor systems and provers, to bottle-fillers, homogenisers, freezers and fryers. as a result, the company has built up unparalleled expertise in the areas of bearings, seals, lubrication, mechatronics and services for this industry, and can provide suitable solutions for any food or beverage manufacturer or processor. now their knowledge and experience of the industry allows them to deliver a number of important benefits, including: Increasing mean time between equipment failures Increasing efficiency and maximising output Improving hygiene by eliminating conditions that foster food-borne illnesses Reducing risk of injury to operators and maintenance staff from repetitive tasks, heavy loads, and slippery or potentially hazardous environments IF yoU haD to DESIgN thE pERFEct tEStINg gRoUND to pUt EqUIpmENt thRoUgh thE toUghESt chaLLENgES, yoU coULD Do a Lot woRSE thaN BaSE It oN thE opERatINg coNDItIoNS FoUND IN thE FooD aND BEVERagE pRocESSINg INDUStRIES. So whEN yoU’RE LookINg FoR BEaRINgS to opERatE IN thIS ENVIRoNmENt, yoU caN’t aFFoRD to chooSE aNythINg LESS thaN thE BESt. David oliver Global food & Beverage segment manager, skf FooD AND BEVERAgE PRo it’s meat and d
  • 17. 17 Focus on Food and Beverage Watch your waste sKf can also help producers and manufacturers meet the requirements for iso 22000 on food safety, and satisfy increasingly tough environmental legislation by reducing waste, cutting down water and lubricant usage, and minimising the impact of washdowns on local ecosystems. They can provide nsf-approved food-safe lubricants, and have the knowledge and expertise to allow food and beverage organisations to improve the efficiency of machinery and auxiliary equipment, from electric motors and pumps to ovens and refrigeration systems. Maintenance meltdown An ice cream manufacturer came to skf with a problem caused by the main gearbox and chain drive in one of their hardening tunnels. They were scheduling maintenance every 12 months to avoid catastrophic failure. skf conducted a root cause failure analysis, which revealed an issue with the ‘breathing’ of the gearbox, caused by air expansion behind the seals, leading to water ingress. The sub-zero temperatures required for freezing, chilling and cooling processes demand frequent maintenance. during cleaning, temperatures can change rapidly – leaping from sub-zero to 35°c – causing air to expand within the bearing and leading to ‘breathing’ problems. This allows water or moisture to enter the bearing, resulting in corrosion and lubricant contamination and degradation which, together with frozen water and other factors, can lead to premature bearing and seal failures. skf recommended skf stainless steel deep groove ball bearings with food Grade solid oil, a cartridge arrangement containing ecoflon 4 seals, and a flinger outboard of the gearbox vertical output shaft. As a result, the ice cream manufacturer has been able to increase mean time between repair to 18 months. You can find out more about sKf’s solutions for the food and Beverage industry at www.skf.com/uk/industry-solutions/food-and-beverage It’s sure to give you plenty to chew over. oCESSiNg? drink to SKF
  • 18. Focus on Food and Beverage 18 ISSUE 18 www.eriks.co.uk/knowhow rocol, the leading UK food-grade lubricants manufacturer, has become the first in the UK to add metal-detectable plastic actuators and caps to its aerosol spray can packaging. These innovative features massively reduce the risk of foreign object contamination during food and drink processing because – unlike traditional actuators and caps – they can be detected using the standard metal detection equipment installed in many food and drink processing plants. if they become loose in food and drink processing areas, the patent-pending deTeXTm caps and actuators – now used on all foodlUBe aerosol cans – can be quickly identified and removed. so production downtime is minimised, and the risk of batch contamination is reduced or eliminated. not only are the components easily detectable, but they are also manufactured from safe materials deemed acceptable by the Us food and drug administration for use in food processing plants. and of course, foodlUBe itself has a long-standing nsf registration, and rocol has corporate iso 21469 certification – both of which offer crucial safety assurances about lubricant formulation. A cap on downtime rocol marketing manager Joanne ferguson explained that, “the addition of deTeX caps and actuators represents another important step in helping food and drink processors avoid costly downtime, product recalls and the risk of reputational damage. “We are continually looking at new ways to help address safety risks, and this includes utilising new technology like DETEX wherever possible. Our corporate strength as part of the global ITW Group gives us privileged access to developments of this kind.” foodlUBe products are available for a wide range of applications across processing plants in the food, drink and clean industries. The foodlUBe aerosol product is a chain lubricant, which is ideal for lubrication of all types of drive and conveyor chains. its outstanding penetration properties ensure it lubricates where it’s needed, and it goes on lubricating for longer thanks to its high resistance to water wash-off, and its water displacing properties. The lubricant, which has a tenacious low drip formulation and good load carrying capacity, operates in the temperature range –20°c to +150°c (+180°c for short periods). like all foodlUBe products it is nsf h1 registered, which means it has been independently assessed and deemed safe for processing equipment used to produce food and drink for human consumption. foodlUBe chain fluid and foodlUBe extreme food grade grease – for extremely wet applications – are also available. USINg FooDLUBE FooD-gRaDE LUBRIcaNt FRom RocoL IN FooD aND DRINk pRocESSINg appLIcatIoNS IS Now SaFER thaN EVER. BEcaUSE Not oNLy IS thE LUBRIcaNt aS SaFE aS It’S aLwayS BEEN, BUt Now ItS packagINg IS SaFER too. FooDLUBE® has safety in the can
  • 19. Focus on Food and Beverage 19 Performanceyoucantrust PATENT PENDING One more step in food safety. ROCOL® , the UK’s first ISO 21469 Certified lubricants manufacturer, launches unique DETEX™ Technology. DETEX™ metal detectable components are designed to assist food processing plants in meeting strict HACCP requirements. METAL DETECTABLE PLASTIC COMPONENTS ROCOL FOOD SAFE MAINTENANCE AEROSOLS Visit www.rocol.com or call +44(0)113 232 2600 for further details ISO 21469 Certified
  • 20. Focus on Food and Beverage 20 ISSUE 18 www.eriks.co.uk/knowhow It takES oNLy oNE SmaLL BUt cataStRophIc LapSE IN hygIENE StaNDaRDS to RUIN a BRaND’S REpUtatIoN. howEVER, It takES oNLy oNE EFFIcIENt maNUFactURER oF cUStomER SoLUtIoNS to pLay a cRItIcaL RoLE IN pREVENtINg pRoBLEmS, aS wELL aS INcREaSINg VaLUE cREatIoN IN FooD aND BEVERagE maNUFactURINg. that oNE maNUFactURER IS FESto. andrew macpherson industry segment manager GB food and Beverage industry Fresh from the
  • 21. Focus on Food and Beverage 21 cost-efficiency and consistently high hygiene standards are always going to be priorities for automated food production. But with increasing demand for product, packaging and pack size variation, there’s a need for fast set-up times and a high degree of modularity in production plant too. fortunately, through single sourcing, process and factory automation technology from festo, food production can be made more efficient and still stay safe. Automation everywhere festo products have a place at most stages of the food production process, where their efficiency, hygienic standards and resistance to harsh environments make them indispensable to safe productivity. for continuous production processes – like mixing and stirring, sterilisation, pasteurisation, homogenisation, filtration, dosing, weighing, filling and storage – automation means reliability. semi-rotary actuators and linear drives open and close process valves throughout the plant, and high quality air preparation (defined by iso standards) also plays an important role in ensuring hygiene and extending the reliability and life of the control system. in the splash zone of food processing operations, automation equipment doesn’t come into contact with food. But corrosion- proof design is mandatory, as water splashes, cleaning agents or dripping food may damage drives and valve terminals, proximity sensors and fittings. With decentralised control, splash resistant, clean design valve terminals (cdVi) and individual valves (cdsV) can be considered for installation close to the drives, with no need for a protective control cabinet. clean design (cdc) cylinders are designed without sharp edges or corners, ensuring that dirt residues or germs can be completely removed during cleaning. When additional guidance is needed, guided cylinders (dgrf) are available. a very useful dry running seal option prolongs the life of actuators even when the grease inserted during manufacture is completely washed away – usually the death knell of an actuator. naturally, cylinder lubrication and seals have fda certification, and the accessories – such as proximity sensors – are optimised for the environment, and resistant to cleaning agents, heat and mould. Tough cookies When the cooking gets tough, you need a tough and reliable performer. ideal for food zones is the festo stainless steel roundline iso cylinder (crdsnU). its gently rounded profile makes it easy to clean, and its unique, self-adjusting end position cushioning saves time during set-up and maintenance. for harsh environments, users can choose seals from a range of festo modular seals. These include fda-compliant seals for food use with standard cleaning regimes, and seals for unlubricated and intensive cleaning. fKm seals are available for elevated temperatures up to 120°c and acidic environments, while there are hard scrapers for temperatures down to –40°c and for harsh applications as varied as sugar crystals, honeycomb and icy fish scales. End of line packaging for the non-food zone, festo provides a wide variety of handling solutions, with a choice of drives to meet individual customer applications in packaging, labelling, testing and monitoring. our handling experts can select from more than 30,000 standard products and use either servo-pneumatic, electric or pneumatic technology to suit the customer application. systems are delivered fully assembled and tested as ready-to-install solutions. This means not just the hardware but a complete value creation package, with less work for the customer, reduced system design costs, simplified procurement and lower process costs. “Fit and forget is the objective for our customers,” explains andrew macPherson, industry segment manager for the gB food and beverage industry. “no two handling systems are the same. They vary from simple pick-and-place systems to linear and cantilever gantries, 3d gantries, dual rod, and kinematic Tripod robotic systems. “our customers describe their handling task, we deliver a plug-and-work solution directly to the installation cell, and there is no need for complex commissioning,” continues macPherson. Putting an end to waste many companies have declared war on waste, with high energy prices increasing the focus on energy reduction. less machine downtime, and the detection and elimination of leaks in compressed air systems, are crucial. That’s why total productive maintenance, condition monitoring and energy- saving services are key factors in food processing plants. food safety and energy efficiency are not mutually exclusive. on the contrary. While the use of hygienic automation technology from festo helps food remain fresh, so the plants in which it is produced stay fresh and modern – with state-of-the-art festo technology. Festo factory
  • 22. Energy savings 22 ISSUE 17 www.eriks.co.uk/knowhow As a result, alongside increasing efficiency in electric motors, a new whole-system efficiency approach is now emerging, best known by its pumping sector description of ‘wire to water’. Laying down the law legislation is forcing increases in industrial electric motor efficiency. under the eu meps (minimum efficiency performance standard) scheme, from 1st january 2015, newly manufactured 7.5kw and above ie2 rated motors must have variable speed drive (vsd) control, and uncontrolled motors must have a minimum ie3 rating. with ie3 at the upper limit of induction motor efficiency, manufacturers are anticipating ie4 and above with various new technologies. A popular option is motors using high powered “rare earth” magnets, but the raw materials’ cost makes this technology expensive. various attempts at lower cost solutions have been developed, for example, the notable launch of the synchronous reluctance motor from ABB, which in common with the permanent magnet motors, requires a dedicated vsd to operate it. Brazilian manufacturer, weG have an already proven premium efficiency motor which meets the criteria for ie4. This American market ‘nemA’ specification motor uses a conventional design, so does not require any specialised vsd for operation. Driving savings no other technology can deliver the energy savings made possible by reducing the running speed of motor-driven equipment than vsds. so development of this inherently efficient technology has focused on ease of use and performance. however, in the uk market, the carbon Trust energy Technology list – itemising specific technology eligible for enhanced capital Allowances – now places more stringent requirements on vsd technology. The fenner qd series of vsds retained its status on the list thanks to its energy optimiser function within its general purpose controllers. electrical regulations amendments for limiting harmonic distortion have also pushed vsd development towards mitigation of distortion, but most filtering solutions increase the losses in the drive. As an alternative, the fenner qd:hvAc will soon introduce film capacitor technology, addressing the cause rather than the symptoms of distortion, with a slight increase in efficiency to boot. The right gear The equipment coupled to a motor’s shaft varies widely. many systems employ a belt drive to transmit power from one shaft to another. Advances in v-belt and wedge belt technology have led to a five-fold liKe The old song aBoUT The Knee Bone connecTed To The Thigh Bone, eVerY elecTric moTor is connecTed To machinerY. and no maTTer hoW clean, comPacT and efficienT The moTor, WhaT iT’s connecTed To maY noT Be. SAViNg ENERgY FRoM ‘THE WiRE To THE WATER’ mark maher Technical manager eriks uk, Technology centre - drives
  • 23. Energy savings 23 increase in the power a single belt can transmit, and reducing the number of belts required naturally increases a drive’s efficiency. synchronous belt drives are even more efficient, but not always the most suitable – if noise is a concern, for example. The drives’ efficiency depends on correct installation, with particular reference to pulley alignment, belt tensioning, and the condition of the pulley grooves. Gearboxes are often employed to convert the motor shaft’s high speed into more usable high torque, lower speed motion. worm gears have been favoured for their compact size, and low initial cost, but this is negated by the high running cost compared to the equivalent helical gear train. of course, for any mechanical system, correct shaft alignment is key for achieving the potential efficiency. misaligned shafts will increase bearing loads and fatigue stresses within the machine – not just using more energy, but also reducing service life. Exceptions to the rule centrifugal pumps and fans are a unique equipment category, because their output is not uniformly related to shaft speed. instead, fluid pressure and shaft torque vary with shaft speed. The ‘cubed law’ states an approximate cube relationship between shaft speed and power requirement, which is true for fans and for pumps which do not have to lift the fluid very high. conversely, for a pumping system moving water to a height, the reduction in pressure eventually becomes a problem when there is not enough pressure to lift the water, so no flow. A simple test is to compare the pumps’ nameplate pressure with the actual pressure required. if there is excess pressure, large savings can be made, but where the two parameters are close, a speed reduction will soon result in no flow. Adjusting pump and fan speeds to match output to demand – especially where demand changes – is a great way to save energy. it is often implemented using sensors and automatic control, which is now a standard feature in most vsds. ‘Wire to Water’ efficiency This measure of system efficiency can be expressed in many ways, depending on the process. for example, a water pumping station would be measured by the cost of moving a volume of water (kilowatts per mega-litre per day). however, looking purely at whole-system efficiency is not always a fair representation. after all, businesses pay for energy used, not for efficiency. for example, where a pump system has a 20% higher flow than required, assuming that there is adequate pressure, it would be valid to reduce the pump speed. even if we account for additional losses by introducing a Vsd, and perhaps a pump efficiency reduction at the new operating point, it would still use less energy and therefore cost less. This is where absorbed power is dominant. Numeric notes overall system efficiency is the numeric product of the component efficiencies. That is, each component’s efficiency must be multiplied together. This can create a surprisingly low overall efficiency, as shown below: VSD (98%) * Motor (88%) * Gearbox (95%) * Pump (85%) = 69.6% SYSTEM EFFiCiENCY
  • 24. Best practice 24 ISSUE 17 www.eriks.co.uk/knowhow Stock aND StoRERoom maNagEmENt DoESN’t jUSt aFFEct yoUR StoRES. yoUR SUppLy chaIN caN taNgLE Up yoUR whoLE BUSINESS. aND pURchaSINg caN coSt EVERyoNE. kNock-oN EFFEctS FRom thESE aREaS aRE FELt RIght acRoSS yoUR BUSINESS’S EFFIcIENcy, pRoDUctIVIty aND pRoFItaBILIty. BUt aLL yoU haVE to Do IS StEp away FRom thE pRoBLEm – wIth thESE FIVE StEpS that REpRESENt BESt pRactIcE. Step away from the PRoBLEM 1What’s what, and where is it? A part by any other name2critical parts need to be clearly identified and stored where your engineers can find them, quickly and easily. otherwise, a breakdown can become a major downtime disaster. There could be a number of reasons why your critical parts are not currently easy to find. it could be because no-one has ever bothered to identify which are critical and which are not. or perhaps when they’re delivered, there’s no proper process in place to receive them, identify them, label them and store them away in the right place. sort out those issues and you’ve taken the first step towards a better organised, more efficient storeroom – and a more efficient, more productive plant too. one man’s 200mm pneumatic cylinder is another man’s ‘machine one Thruster’, and another’s ‘part no. dnc 100-200’. which is fine when the first man’s pneumatic cylinder is in stock when he needs it. not so fine if a different engineer needs the same part, but knows it by a different name, thinks it isn’t in stock, and orders a new one. And so on, and so on. you could end up with three times as many parts as you need, each one only accessible by the engineer who ordered it and named it. And if some of the over- stocked parts are left unused because the first engineer doesn’t know they are there, they could become unusable through age before anyone discovers them. The simple step to take is to name parts consistently, and ideally with a name which contains all the important information (such as: ‘cylinder, pneumatic, 100mm bore, 200mm stroke’). all too often, storerooms contain more than just parts and supplies. Somewhere in the chaotic, mismanaged depths, they’re also storing up trouble. it may be when there’s a catastrophic machine failure and a critical part isn’t in stock. it may be when an audit discovers money has been wasted re-ordering parts, when there are still several in stock – just wrongly labelled. or perhaps when the right part is in stock in the right place, but because it hasn’t been stored and cared for correctly it’s unserviceable. or maybe there won’t ever be a ‘lightbulb’ moment (or a ‘need a lightbulb and there isn’t one in stock’ moment). instead, you’ll just wonder why a simple maintenance job takes longer than it should, why your engineers are spending less time engineering and more time sourcing supplies, and why productivity is slowly but surely falling. That’s when it’s time to start taking five simple steps to address the problem.
  • 25. Best practice 25 Supply chain or millstone? one step, less walking Talk your way out of trouble3 4 5The more suppliers you have, the more resources you tie up in managing an unwieldy and inefficient supply chain. in fact, if your business is anything like average, 65% of your purchasing resource will be dedicated to controlling just 10% of your purchases – usually your mro spares. however, if you take the important step of consolidating your supplies with one vendor, you not only reduce the resources needed to manage the supply chain, but you can also realise numerous other benefits. such as raising fewer purchase orders (at an estimated cost of £50 each), paying fewer invoices, and incurring lower or no carriage costs. And the more experienced and efficient the supplier – with knowledge beyond the storeroom – the more opportunity you have to realise even greater efficiencies in your wider organisation. especially if you locate the supplier’s representative on- site, for instant access and support that’s always available. some engineers may look like humans, but they’re actually squirrels – storing parts in their own secret stash, so they don’t have to deal with lengthy walk-and-wait times or poor service from a mismanaged storeroom. it’s an unorthodox solution but in many ways it’s the right one. so what you need to do is take the step of legitimising it and controlling it, by providing an authorised ‘secret stash’ in the form of a lineside vending solution. you know what stock is where, who accesses it and when. downtime is minimised. And your engineers become human again. Though they may be even more bright-eyed and bushy tailed. The final step away from the problem is to talk. Talk to the people who deal with stock and storeroom management all day every day, and who also know something about your business – because they deal with that every day too. in other words: your suppliers. Talk to them about all the other steps above, and you may find they are the ones who can help you to achieve them all successfully. But make sure you talk to a supplier who has knowledge beyond the storeroom. who has application, engineering and technical know-how. who has mro expertise, and a process re-engineering capability. And who can deliver benefits you’ll see quantified with signed-off cost savings. In fact, talking to ERIKS could be a step in the right direction. knowhow.eriks.co.uk/onsite julia mullar operations development manager eriks uk integrated solutions
  • 26. “ ISSUE 17 www.eriks.co.uk/knowhow26 as reported in our news pages, we are ‘heading in the right direction’ when it comes to apprenticeships. for example, the department for Business, innovation and skills is making available nearly £49m to boost engineering skills, with the majority of the funding made available to allow employers to bid for match-funding for training schemes that will address specific engineering skills shortages. most of us would agree that we need to inspire and support a new generation of engineers here in the UK but the question is, how? We’re doing our best to inspire young engineers: two high-achieving young employees have recently collected awards, highlighting the success of our ongoing apprenticeship programme and showing the rewards that can be reaped – for employer and employee – by investing in talent. ERIKS chesterfield apprentice Jacob Kane has been awarded the title apprentice of the Year by the institute of engineering and Technology, while colleague liam greveson won the first ever easa (electrical apparatus service association) exceptional achievement award. meanwhile, the debate over how to encourage engineering talent continues to generate opinion, debate and plenty of statistics. concerned that the UK will require 2.2 million employees over the next five to 10 years, The engineer columnist Paul Jackson looked at attitudes to engineering within the education system back in 2012. Jackson discovered that one in five science, design and technology, and maths teachers surveyed by the magazine say they believe a career in engineering is undesirable for their students. however, by 2013, The engineer reported that almost a third of parents, who had previously dismissed apprenticeships as a viable career choice, had changed their views. a survey commissioned by Bae systems and the royal academy of engineering and carried out by Yougov canvassed 2,000 parents of children aged 11-18. it found that 42% had gained a more positive view of apprenticeships in the last year; 29% said they saw such schemes as a viable option for their own offspring but would never have considered it five years ago. (it also found parents on higher incomes were more than twice as likely as those with average incomes to see apprenticeships as good for other people’s children but not their own.) With a strong predicted demand for engineers, perhaps the careers service can help identify potential and promote engineering as a profession? and when we do get apprentices, can we do more to inspire them? We need to make the most of their skills and support personal development so that apprentices truly feel involved. in doing so, those already established in the business can help themselves. When the business suffers from a skills shortage, it’s middle managers that have to step in and sort things out. As this experienced workforce grows older, it is they who will bear the most stress. So, the sooner we recruit, inspire and keep a new wave of apprentices, the better. The Tig More apprentices, less stress “
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