ERIKS Know+How Issue 23, Energy Conservation

THE LEADING MAGAZINE FOR MAINTENANCE ENGINEERS FROM ERIKS
www.eriks.co.uk/knowhow
ISSUE 23
The big picture on energy efficiency
Focus on energy conservation for long term savings p10
Pumping
up value
Should you repair or
replace your pump?
p24
Introducing TIM WOOD
Memorable, helpful, wasteful p18
When minus is a plus
Less energy, more benefits p22
EN
ERGY CON
SERVATIO
N
•FOC
US ON •
Leaking secrets
Discover where the
cash is leaking from
your business p6
Happy ever after
How to make your
coupling last p14

Contents
3
Contents
WELCOME TO KNOW+HOW…
Covering the latest news, industry developments and
technologies, this edition of Know+How focuses on one of the
hottest topics in the maintenance world: energy conservation.
I look forward to hearing from you.
Alan Whetstone
Managing Director, Editor in Chief
UNREGISTERED
Published by ERIKS UK, Amber Way, Halesowen, West Midlands, B62 8WG
With both UK and European
legislation clamping down hard
on energy consumption across the
commercial landscape, the process-
heavy nature of the industrial sector is
right in the firing line. Whilst the pressure
to conserve energy becomes ever
greater, the task is not impossible
and there are a host of different ways
maintenance engineers can streamline
consumption without breaking the bank.
Inside, you’ll be able to read up on some
of the latest trends and products making
the headlines in the energy market, as
well as hearing from a number of leading
industry players on how to tackle energy
conservation. SKF will shed light on
the energy-saving impact of bearings
in motors and drives; Festo investigates
the efficiency properties of electric vs
pneumatic components; and SMC delves
into the seven deadly wastes of the
workplace with ‘Tim Wood’ – but all is
not as it seems. We’ll also address one
of the age-old arguments affecting
maintenance engineers – whether
to repair or to replace, with this issue
focusing on pumps.
We are also very pleased to welcome
Janet Wood of New Power magazine
as our guest contributor. Janet will
dig deeper into the mechanics behind
improving energy conservation, moving
away from a focus on fuel cost to
emphasising the importance of
understanding your processes and
pinpointing where the most savings
can be made.
As ever, the issue will be rounded off
by the TIG, who in this issue ponders
the changing face of the UK’s industrial
landscape, following the decline of many
of the iconic visual reminders of our
industrial heritage.
If you have any comments you would
like to raise on the topics contained in
this issue you can email the editor at:
knowhoweditor@eriks.co.uk or you
can visit Know+How’s own website:
www.eriks.co.uk/KnowHow where
you can register for your own personal
copy, enquire about the subjects and
products discussed or contact one of
the contributors.
LATEST NEWS 04
Solar power cheaper than fossil
fuels by 2020?
Energy from footsteps
£1.3bn offshore wind farm given green light
‘Significant’ oil discovery made in Sussex hills
British economy on track for continuous growth
Six hours of energy saving
IN-DEPTH 06
Where does the cash leak from your business?
TECHNOLOGY UPDATE 08
RX launches new range of industrial
wiping products
ERIKS partners with INOXPA to enhance
valve offering
ERIKS unveils new range of spiral wound gaskets
ERIKS home to most comprehensive
couplings offering
RX gives engineers a helping hand
FOCUS ON ENERGY
CONSERVATION
10
Is your business energy savvy? p10
Planet Plus – Surveying for savings p12
Searching for closure p13
Couple counselling p14
The right choice p16
The seven deadly wastes p18
Going beyond zero p20
Let us spray and save energy p22
THIS MONTH’S DEBATE 24
Repair or replace
TIME SAVINGS 26
Delivering the milk on time
BEST PRACTICE
When saving money on gearboxes
costs you money
28

EN
ERGY CON
S
ERVATION
•FOC
US ON •
For Fenner®
, call ERIKS.
Energy Efficient Fan and
Centrifugal Pump Control
The Fenner QD:HVAC sets a new standard for
dedicated fan pump control whilst retaining
the ease of use you come to expect from Fenner
inverters. Fenner QD:HVAC has an innovative
design, combined with robust performance to
provide powerful flow control and reliability in a
compact drive.
Energy optimisation
Energy monitoring
Built in cascade control
Multiple fan operation
Resonance avoidance
QD:HVAC Inverters
Energy Efficient
98.8
Energy Efficient
95 Energy Efficient
96
Energy Efficient
98
EXAMPLE SAVINGS BASED ON A 45KW LOAD
Power
Flow %
Input to fixed speed systems
Input to fixed speed systems
Calculation is based on a typical estimated factory working week and
energy costs, including estimated components and installtion costs.
Investment payback
in 8 months
Savings of over
€31,000 in 5 years
35,000
30,000
25,000
20,000
15,000
10,000
5,000
0
0 1 2 3 4 5
€
Hours
Using a Fenner QD:HVAC drive to reduce
the fan speed during periods when
maximum flow is not required provides
the maximum possible energy savings.
www.fptgroup.com
ERIKS UK Amber Way, Halesowen, West Midlands, B62 8WG
Tel: 0121 508 6000 Fax: 0121 508 6255
T : 0845 006 6000
Fenner is a registered trade mark of J. H. Fenner Co.
A 20% REDUCTION IN SPEED
CAN REDUCE ENERGY
CONSUMPTION BY UP TO 50%.
INSTANT POWER SAVINGS: With variable speed
control, HVAC immediately reduces power usage
compared to fixed speed systems.
knowhow.eriks.co.uk
facebook.com/eriksuk
twitter.com/eriks_uk
ERIKS UK

Latest news Latest news
ISSUE 23 www.eriks.co.uk/knowhow4 5
‘Significant’
Oil discovery
made in
Sussex hills
UK set for back-to-back economic growth,
fuelled by manufacturing exports
THE BRITISH ECONOMY IS WELL ON TRACK FOR
CONTINUOUS GROWTH OVER THE NEXT TWO YEARS,
HAVING INCREASED FASTER THAN INITIALLY PREDICTED.
According to the leading business group, the CBI, the UK economy
is forecasted to have grown by 2.4% by the end of 2015, and it
predicts a further increase of 2.5% for 2016. Whilst external factors
such as a sluggish Eurozone have resulted in a slightly revised
forecast for growth, the home-grown prospects remain buoyant.
In the same vein, the British Chamber of Commerce has reported an
overall growth of manufacturing export orders and sales over the
first quarter of the year. Over 46% of the companies surveyed
reported a growth in export orders, and 43% recorded an increase
in export sales compared to Q4 2014.
John Longworth, director general of the BCC, said: “Manufacturers
are turning to export markets abroad to fuel their growth ambitions
as the slowdown in domestic growth persists. Encouragingly, the
increase in export sales and orders has come about in spite of the
rise in the pound against the euro over recent months - a credit to
the strength and expertise of the UK’s manufacturing sector.”
Six hours of
energy saving
The ERIKS’ Energy Conservation Operation Day – held in
Northampton on 17th June in conjunction with Festo – proved
interesting, informative and enjoyable for its 90 attendees.
With less than six months to go before the results of ESOS
assessments have to be submitted to the Environment
Agency, visitors to the ECO Day heard timely advice
from experts on the causes of energy loss, along with
solutions for energy conservation.
Presentations on thermographic surveys using infra-red
equipment, maximising energy savings through creative
lighting controls, energy-saving opportunities with pumps,
and cost-saving ideas for compressed air all helped to
ensure the day provided invaluable guidance and know-how,
combined with practical solutions.
Stimulating and simulating
Many visitors made the most of the opportunity to network
with ERIKS experts and industry peers. Most also spent time
browsing around the event’s exhibition, which included displays
from Festo, Grundfos, SKF, CAMfil, WEG and Inoxpa, as well
as ERIKS Pumps, Condition Monitoring and Lighting Solutions.
The day included a tour of Festo HQ, and concluded with
a Prize Draw, in which Aston Fuller of Ardagh Glass won
a presentation boxed pen and pencil set.
Solar power could be cheaper
than fossil fuels in five years
Solar power could become cheaper than fossil fuels
by as soon as 2020, according to an industry body.
The Solar Trade Association (STA) believes the new
government could double the solar ambitions of the previous
administration with just a ‘little more expenditure.’
As part of its new report, Solar Independence Plan for Britain,
the STA outlined that with buy-in from 2.1m homes; 24,000
commercial and community schemes; and 2,300 quality solar
farms, the new government can guide rooftop-generated
electricity to parity with gas power station prices by 2020.
The next (foot)step in energy generation
Energy from footsteps could be the next big thing in the
world of alternative energy, after British firm Pavegen has
started a crowd funding campaign to develop an energy-
generating floor.
The technology works by converting the movement and
weight of the person walking across the floor into power,
via an electromagnetic generation system. When footstep
pressure is applied, a flywheel rotates and the energy from
the step is stored in the inertia of the flywheel.
It has unveiled its first urban installation in London, having
already trialled the technology at Heathrow Airport, the
White House, and a Brazilian football pitch.
£1.3bn offshore wind farm
given green light
E.ON has been given the go ahead to construct a 400mW
wind farm 13km off the Suffolk coast, following significant
financial commitment.
The 116 turbine strong project, known as the Rampion
Offshore Wind Farm, will occupy 72km² and represents an
investment of £1.3bn from E.ON and Green Investment Bank.
With work starting in June 2015, it is due for to be
completed by 2018. The project is expected to reduce
CO2
emissions by up to 600,000 tonnes a year and create
between 250 and 300 construction jobs, as well as 65
permanent MRO jobs once the wind farm is operational.
The discovery, which equates to more than double the amount of
oil produced by the North Sea over the last 40 years, is one of
the largest onshore discoveries in the UK to date. However, only
a fraction of it could be recovered, according to exploration firm
UK Oil Gas (UKOG).
Having analysed results from a preliminary well drilled at Horse
Hill, near Gatwick; the local area could hold 158 million barrels
of oil per square mile. The company believes between 5 and 15%
of the oil is recoverable, which means that the discovery – when
combined with other oil production sites across the South East –
could cater for up to 30% of the country’s demand. What’s more,
UKOG believes the resources could be accessed without
resorting to fracking.
UKOG chief executive, Stephen Sanderson, commented: “We
think we’ve found a very significant discovery here, probably the
largest (onshore in the UK) in the last 30 years. Based on what
we’ve found here, we’re looking at between 50 and 100 billion
barrels of oil in place in the ground.”
UP TO 100 BILLION BARRELS OF OIL COULD HAVE BEEN
FOUND IN SOUTHERN ENGLAND.
Energy
ERIKS ECO Event
Date Time; Wednesday 17th June 2015, 10:00 to 16:00)
Location; FESTO Caswell Road, BrackMills, Northampton, NN4 7PY
EEnergy
nergy
CConservation
onservationOOperation
peration
Festo’s Airmotion Ride attracts attention during the breaks.
All the presentations and overviews from the day are available on knowhow.eriks.co.uk

In-depth
ISSUE 23 www.eriks.co.uk/knowhow6 7
In-depth
FROM YOUR
BUSINESS?LEAK
WHERE DOES THE CASH
THE CAUSE CAN’T BE SEEN. IT CAN’T BE TOUCHED. BUT THE LOSSES IT RESULTS
IN ARE NO LESS REAL. THERE COULD BE THOUSANDS OF POUNDS LITERALLY
LEAKING AWAY FROM YOUR BUSINESS – AND IT’S A PROBLEM ACROSS THE
WHOLE OF UK INDUSTRY. YET MOST PEOPLE AFFECTED STILL BELIEVE THE
PROBLEM DOESN’T EXIST, EVEN WHEN IT IS, LITERALLY, UNDER THEIR NOSES.
If you haven’t guessed yet what the problem
is, then the chances are that you are one of
those people who deny it’s a problem at all.
The issue is compressed air leakage, and
the common attitude is that “air is free, so
how can it be losing me money?”
In fact, compressed air is not a no-cost or
low-cost resource. So if it’s being wasted,
or used inefficiently, then money is, in every
sense, disappearing into thin air.
60% losses
On some industrial sites, as much as 60%
of the total compressed air they generate
is lost to leaks. Even an average site leaks
30% of its compressed air.
According to Mark Stone, Product Manager
at FLEXION Fluid Power, “Big leaks, such
as a drain cap on a filter regulator, can cost
up to £5,000 every year. Even small leaks,
emanating from a control panel, main
air drop or push-fit connection, for example,
can cost hundreds of pounds in compressed
air annually.”
But the leak is not the end of the problem.
A costly vicious circle
Compressed air isn’t “as free as air”
because the compression process
requires equipment, uses energy to drive
the equipment, and the equipment incurs
additional labour, parts and lubricant costs
to remain in operation.
So an unidentified and unrepaired leak
wastes the cost of production of the
compressed air. But that’s only the start.
A leak also means the air-driven equipment
is not being supplied with compressed air at
the correct pressure. This means it will not
perform at its optimum, and its efficiency
and productivity will fall. At the same time,
the leak effectively creates a greater demand
for compressed air, which the compressors
will work harder to satisfy. This in turn
increases their own demand for energy,
which reduces the plant’s overall energy
efficiency, increases its energy bills, and
ultimately increases CO2
emissions.
Since every additional 1kW of electricity
used generates another 0.5kg of CO2
,
unnecessary and excessive energy use not
only has implications for your bottom line,
but also for your CSR policy and for the
environment.
Plugging the leak
Think of a compressed air leak as a leak
of cash, and suddenly fixing the problem
becomes a priority. And it’s a highly
cost-effective step to take.
A leaking loose connection on an isolation
valve could be costing hundreds of pounds
annually in lost compressed air. Yet it can be
fixed in a matter of minutes, probably for as
little as £25.
But sometimes, a leak may merely be the
most easily identified source of compressed
air losses. Compressed air can also generate
unnecessary indirect losses and costs,
which may be harder to spot without the
necessary technical know-how.
Supplying compressed air to an idle plant,
or using higher pressures than necessary,
are both a waste of air, energy and money.
So is failing to use the most energy-efficient
components.
Taking a systematic approach to
compressed air management – from leak
detection to system design – may lead to
some compressors no longer being required,
which will obviously lead to significant
energy and maintenance cost savings.
For some applications, the most cost-
effective option may even be to switch
to an alternative technology entirely.
Mark Stone
Product Manager,
FLEXION Fluid Power
Compressed Air Savings Programme
It’s to help industry find and fix compressed
air leaks, and make significant energy
and cost savings, that FLEXION – the
international fluid power brand of ERIKS –
has established the Compressed Air
Savings Programme.
The Programme comprises three elements:
1. Application Audit – an experienced
FLEXION team uses a specially
designed ultrasonic detector to complete
an audit for a medium-size plant in
around three hours.
2. Full Report – delivered immediately
after completion of the audit. The report
lists the leaks detected, their size, and
their estimated cost to the business.
3. First Fix – basic on-the-spot repairs,
where possible. These can include
remaking joints, and/or replacing fittings,
gauges and other non-active parts. First
fix capability depends on safe access to
the equipment, which normally requires
isolation of the mains air supply. A full
bill of the materials required to effect all
recommended repairs identified in the
survey will be provided.
Through this Programme, FLEXION has
already achieved significant signed-off
cost savings on compressed air use for
businesses across UK industry.
If you would like to find where cash is
leaking from your business, visit the
FLEXION Compressed Air Savings
Programme page of the ERIKS website
www.eriks.co.uk/flexion or contact
your local ERIKS Service Centre.

Technology update Technology update
8 9ISSUE 23 www.eriks.co.uk/knowhow
RX launches new range of
industrial wiping products
The portfolio, which is exclusive to ERIKS,
includes general purpose and speciality wet
wipes and cloths, and is available in a variety
of durability levels to cater for different
market sectors and the taking care of the
diverse liquids involved.
The RX range of wet wipes have been
designed as a go-to product for general
everyday hygiene applications, as well as
covering more technical sanitising solutions,
such as when precision wiping and ultra-low
linting wipes are essential. All of the products
are dermatologically tested and comply with
the European Standards, meaning they are
effective against H1N1, Salmonella, Listeria
and E-Coli, amongst others.
In order to offer end users
further peace of mind when
heavy duty workstation
hygiene is a must, or when
small-scale accidents occur,
the new range of industrial
cloths and wipers are highly
absorbent and durable enough
to a number of different
liquids, including solvents.
The new RX industrial wiping
portfolio is suitable for use across a wide
range of applications, but can offer an ideal
solution for food processing, healthcare,
transportations sectors, as well as general
workshop maintenance.
The new range has attained the maximum
score – 4.5.4.4 – across all categories for
EN388, which protect against mechanical
risk, to offer all-round protection for a
number of different industrial applications.
Available in five different sizes, the RX
Safe5 glove features a close-fitting yet
breathable seamless liner to offer optimum
dexterity, with a durable Nitrile palm coating
to provide both an excellent grip and
resilient all-round protection. It also features
an elasticated knitted wrist-cuff to ensure a
secure fit and keep the hands free from
dust and debris.
The RX Safe5 range is suitable for use
across a variety of industrial maintenance
and repair applications, including component
handling and general assembly, across a
number of different industries, such as
automotive, construction and engineering.
Available in a number of different designs,
the INOXPA range is specifically designed
for use within the food and beverage,
pharmaceutical, cosmetics, and chemicals
industries.
Included within the new INOXPA offering
is the widely-used seat valve range, which
is available in a number of different
configurations: a single-seat pneumatically
operated shut-off valve; a manually actuated
single-set valve; a divert seat valve; a tank
bottom seat valve; a regulating seat valve;
and a hygienic mix-proof double seat valve,
which simultaneously allows two fluids to
pass through the valve, whilst preventing
cross-contamination.
Alongside the seat valves, ERIKS will
also be stocking a range of manual and
automatic butterfly valves; diaphragm and
pinch valves; ball valves, for use with viscous
fluids containing solid particles; check,
or non-return valves; overflow valves for
pressure bypass systems; and vent valves,
for the release of trapped air in suction
pump applications.
For more information, call 0116 272 7300
or email sales@econosto.uk.com
RX HAS LAUNCHED A NEW PORTFOLIO OF HIGHLY ABSORBENT INDUSTRIAL WIPING PRODUCTS
TO HELP COPE WITH HEAVY DUTY CLEANING TASKS AND SMALL-SCALE SPILLAGES.
RX HAS RELEASED THE LATEST IN ITS LINE OF PERSONAL
PROTECTIVE EQUIPMENT (PPE) – THE RX SAFE5 GLOVE, WHICH
MEETS THE MOST STRINGENT EUROPEAN SAFETY STANDARDS
FOR GLOVES FOR MECHANICAL PROTECTION.
ERIKS IS NOW STOCKING A WIDE RANGE OF INOXPA SANITARY VALVES TO
CONTRIBUTE TO ITS BROADEST INDUSTRIAL VALVE OFFERING TO DATE.
ERIKS partners with INOXPA
to enhance valve offering RX gives engineers a helping hand
with ultimate protective glove
For more information, please visit
eriks.co.uk/RX-Safe5-Gloves/4130
eriks.co.uk/RX-Wiping-Products/4131
The Leader Gasket Technology (GT) range
is available in four different styles: S – spiral
winding only, which consists of a wound
gasket but with no inner or outer ring; SI –
a spiral wound gasket with a solid metal
inner ring designed to minimise turbulence
in process material flow, and prevent inward
buckling of the spiral wound gasket
element; SR – a spiral wound gasket
with a customisable outer ring; and SRI –
a gasket with a spiral winding and both
an inner and outer ring.
The Leader GT range is suitable for both OEM
and MRO applications across a number of
different industries, including oil and gas;
chemical; petrochemical; pharmaceutical;
power generation; hygiene; and marine.
What’s more, all gaskets can be
manufactured in our European facilities
to bespoke specifications using ERIKS
Gasket Technology’s state of the art
engineering and design studio, including
ASME B16.20 and in line with ISO 9001.
eriks.co.uk/Gaskets
ERIKS has been at the forefront of the
design, manufacture and supply of
gaskets for over 40 years and has
launched a new range of spiral wound
gaskets which can be used across all
relevant industrial applications.
Technical Support
across extended range
AS A VITAL ELEMENT IN MOST
POWER TRANSMISSION SYSTEMS,
ERIKS OFFER ENGINEERS THE
MOST COMPREHENSIVE COUPLING
SELECTION AVAILABLE.
Given the drastic consequences
associated with incorrectly specified
couplings, the ERIKS offering boasts
a number of market-leading brands,
supported by a dedicated Couplings and
Drives Centre of Excellence. As such,
any potential customer has access to
unparalleled industry knowledge and
expertise to ensure they are sold the
most appropriate coupling solution for
their application.
ERIKS exclusively
stocks a wide range
of couplings from
one of the most
renowned brands
worldwide, Fenner.
From the basic Jaw
Couplings to Fenaflex
Tyre Couplings which
is regarded as the
ultimate in machine
protection, the Fenner
range has it covered.
Alongside Fenner, ERIKS is also the sole
supplier of Falk couplings including
Steelflex, Wrapflex and Lifelign.
Well known for their durability in critical
applications, Falk couplings can be used
across a huge range of industrial
applications, and offer one of the lowest
Total Cost of Ownership (TCO) ratings on
the market.
What’s more, ERIKS’
in-house machining
centre can produce
bored and keyed
couplings modified to
precise and bespoke
requirements.
eriks.co.uk/Couplings
ERIKS unveils new range
of spiral wound gaskets

Focus on Energy Conservation Focus on Energy Conservation
the government has given industry a push
towards better efficiency, requiring many
companies to measure and report their use
or carbon emissions. The ESOS certificate
scheme is the latest approach to audit – one
that has yet to convince companies, and
perhaps that is why by the end of May fewer
than 50 of some 14,000 firms who have to
demonstrate compliance had done so.
Whether or not you want to report it,
understanding your usage is fundamental
to reducing it. Metering and submetering
(between, say, areas of a building or parts
of a factory line) is improving all the time
and although domestic and microbusiness
customers are still on simple meters read
annually, most businesses now should
at least have meters that measure
consumption half-hourly. That means you
can identify and remove stray usage that is
unnecessary. It also means that you can be
aware of when you use most energy. Again,
this doesn’t affect domestic and very small
businesses yet, but most others will have a
time element in their charges – because
there are several components in your bill,
like the network charge and the cost of
power, that can rise dramatically at peak
times of the day. You are already paying for
that, even if your supplier absorbs it into a
flat tariff. But if you can understand when
those peak hours are and focus your energy
efficiency efforts on those periods, payback
will be quicker.
Finally, it’s worth thinking about water.
Scientifically, water is a strange and
interesting liquid. Among those interesting
features are that it is extremely heavy to
move around, and that it takes an inordinate
amount of energy to heat it up. That means
that for many companies a good proportion
of the energy bill is for hot water use,
whether that’s for general heating,
processes heat, or just making sure it’s in
the right place. Using water more efficiently
can mean big energy savings.
Once again some of that is very low hanging
fruit indeed – turning down the heating
when the building is out of use – and water
saving devices are increasingly available.
And again, if you want ideas you should get
your supplier to step up. Businesses are
about to gain some more market power
here: soon all business customers will be
able to switch their water company as easily
as they do their energy supplier. Water
companies afraid of seeing customers slip
away have already identified help on water
efficiency as a key opportunity to hold onto
their customers, so contact them and see
what they have to offer.
OIL AND GAS PRICES HAVE BEEN TUMBLING
GLOBALLY OVER THE LAST YEAR, DRIVEN DOWN BY
A BOOM IN SHALE GAS PRODUCTION AND GENERAL
OVERSUPPLY ON THE WORLD MARKETS.
But that high level story of lower energy prices
shouldn’t mean energy efficiency slips down
the agenda for businesses. Oil and gas prices
do influence the price you pay for gas and
electricity at the meter, but they are a relatively
small amount of the total, and even the GB
energy regulator has noted that while your
bill rises fast when commodity prices
increase, it takes a long time to fall when
they go down. In the long term, it will always
make sense to reduce your energy bill.
What we have learned over the past decade
is that there are huge savings to be made.
But they may not be immediate.
There is no politician in the energy sector
that does not like to end a speech with a
flourish on energy efficiency. It’s the one
energy measure everyone can agree on, and
I’ve heard it described as “completely free”,
and even as “negawatts”. That’s too simplistic:
it pays back, sometimes quickly and
sometimes slowly, but there is generally
some cost to implementing it, even if that
cost is in learning new habits.
The government has tried to provide more
impetus for companies to consider their
energy use and take steps to reduce it.
Sometimes that takes the form of taxes, so
that energy-saving businesses could make
savings on both their energy bills, and on
extra taxes like the CRC energy efficiency
commitment, which are levied according to
the amount of energy used.
There are some relatively simple early steps
that any business should take.
Lighting is a good example. It is familiar and
often unnoticed, so it seems unlikely that
changing it can make much difference to
the bill. Nothing could be farther from the
truth – in fact, the effect is visible on a
national scale. Electricity system operator
National Grid has seen a 3% reduction
in domestic electricity demand since
customers started switching from old-style
light bulbs to new compact fluorescents,
and shifting to LEDs will cut that by at least
another percentage point. Businesses can
cut their lighting costs by a third, and it is
still for many the quickest and easiest way
to start saving energy. Another is checking
your energy still does what you expect. Is
the heating timed right? Do people switch
off lights and power where it’s not needed?
These are obvious and possibly simple
changes. There are many more options, and
many companies out there that can help you
improve energy efficiency in the long term in
exchange for an initial outlay. But as we’ve
seen, there will be a cost.
How can you fund that? There are some
differing schools of thought here. One says
that you should grab the low hanging fruit
immediately and take the savings. The
alternative is to look at the bigger picture:
package up the cheapest and easiest
changes with some that require more initial
outlay, so fast savings fund some of those
that take longer to make a return.
You should get your energy supplier and
equipment sellers working for you here.
Some have stepped into the market gap
between companies’ wish to save energy
and their inability to pay upfront. That might
mean easier payment terms or more
innovative schemes that recoup the cost
of energy-efficient equipment from energy
savings over time.
Fundamental to saving is knowing what you
use and when. That’s another point where
Janet Wood
Editor, New Power
EN
ERGY CON
SERVATIO
N
•FOC
US ON •
About our guest editor
Janet Wood is editor of New Power,
a monthly report and database on UK
power sector development.
She has been a journalist covering
the power and energy sector for 20
years, covering technology, policy
and politics as editor of magazines
including Power Engineering, Asian
Electricity, Middle East Electricity and
Utility Week.
She is also the author of two books
for the Institute of Engineering and
Technology (IET), on nuclear energy
and on local-scale heat and power
projects in the UK.
IS YOUR BUSINESS
ENERGY SAVVY?

Focus on Energy Conservation
12 ISSUE 23 www.eriks.co.uk/knowhow
1312 ISSUE 23 www.eriks.co.uk/knowhow
Bearing Shield and Seal Bearing Comparison Table
ZZ VV DDU
Dust resistance Normal Good Excellent
Water resistance Unsuitable Unsuitable Excellent
Torque Very low Very low Normal
Speed High High Normal
Grease retention Normal Good Excellent
BEARINGS CAN BE FOUND IN A VAST RANGE OF
MACHINERY INCLUDING ELECTRIC MOTORS, PUMPS,
FANS AND ELECTRICAL APPLIANCES, AND MANY OF
THOSE BEARINGS WILL BE MADE BY NSK – THE
WORLD’S LARGEST MANUFACTURER OF DEEP GROOVE
BALL BEARINGS. EVERY PRODUCT IMPROVEMENT
AND NEW DEVELOPMENT FROM NSK CAN MAKE
AN IMPORTANT CONTRIBUTION TO LOWER FRICTION
AND MORE ENERGY EFFICIENT OPERATIONS.
The deep groove ball bearing is the world’s most widely used type of bearing. In general industrial applications, many deep groove ball
bearings are classified as “sealed for life”, meaning they are supplied with a closure on each side of the bearing and cannot be re-lubricated.
Because bearings are a critical component in machines, bearing lifetime is directly related to machine uptime, so choice of closure is an
important decision for a machine designer or maintenance operator.
Non contact ZZ metal
shields are the most basic
type of bearing closure.
These shields, which are
treated with a special
anti-corrosion zinc coating,
help to retain the grease
within the bearing and
protect the bearing from
large contaminants. There is no speed
restriction with ZZ shields, meaning they are
commonly found in high speed applications
such as motors.
NSK also offers “VV”
seals. The non contact VV
rubber seal is moulded so
that its sealing lip sits
tightly in a unique groove
found on the inner ring of
all standard NSK deep
groove ball bearings
(10mm bore diameter
upwards). This creates a very fine clearance
labyrinth, resulting in zero seal drag, low
starting torque and no reduction in bearing
limiting speed. These properties are very
important when energy efficiency and low
power loss are critical, e.g. small electric
motors. Grease retention and contamination
protection are also greatly increased
compared to the ZZ shielded design.
The seal groove on the
inner ring of all standard
bearings has also allowed
NSK to develop a high
performance contact seal
design. The NSK “DDU”
seal is designed with 3
sealing lips; one lip forms
a contact with the side
face of the inner ring groove, the other
sealing lips form tight non-contact
constrictions at either side of the contact
sealing lip. This triple lip sealing mechanism
gives excellent protection against dust and
water contamination. The axial sealing lip
means that grease leakage is significantly
reduced compared to standard seals,
particularly in outer ring rotating
applications. The innovative seal design has
been well proven in the field, with numerous
cost savings achieved simply by switching
from a standard rubber seal to an NSK
DDU seal. DDU seals are standard on all
NSK deep groove ball bearings above
10mm bore diameter.
NSK’s different closure options allow
ERIKS customers to choose a bearing for
any application condition, be it high speed,
low torque, water splash, dust protection,
grease retention or a combination of these.
Using the NSK high performance sealing
options ERIKS have been able to work with
a large number of MRO accounts to realise
significant cost saving benefits.
SURVEYING
FOR SAVINGS
ONE OF THE BEST WAYS TO REDUCE ENERGY USE – AND THEREFORE SAVE ON
ENERGY COSTS – IS TO FIND OUT WHERE YOU ARE WASTING ENERGY IN THE
FIRST PLACE. THAT’S HOW ERIKS RECENTLY HELPED TWO DIFFERENT
MANUFACTURERS MAKE SIGNIFICANT COST SAVINGS.
A large dairy manufacturer was losing
heat energy due to damaged and missing
insulation, on the steam service lines for
their production and Clean in Process
equipment. An ERIKS Condition Monitoring
team carried out a survey of all the customer’s
steam services, and found far more than
the customer bargained for.
In fact, the survey identified not just a
handful of areas where heat and energy
were being lost, but a staggering 93 different
locations. These added up to a cost to the
customer of almost £50,000 a year.
Having identified the problem areas,
ERIKS quoted for repair and replacement
of lagging and insulation to eliminate the
losses. The customer also acquired other
quotes, but ERIKS’ was by far the most
competitive.
Not surprisingly, ERIKS won
the contract, and carried out the
necessary work. As a result, the
customer will save £15,573.13 in
the first year, and £49,573.13 in
subsequent years.
Performing under
(less) pressure
A food manufacturer also had an issue
with energy use, involving pumps which
provide their high-pressure water for
washing-down.
This time, in addition to the pump audit
requested by the customer, ERIKS Pumps
specialists carried out a pipework survey
to identify potential improvements in the
wider system.
The existing pumps were not only old, but
also labour intensive, noisy, and consumed
3,510kW per week. At peak periods, they
simply couldn’t cope with demand. However,
the pump audit identified the possibility of
reducing the water pressure required, due
to improvements in cleaning chemicals
since the original pumps were installed.
Meanwhile, the pipework survey revealed
several hundred metres of redundant
pipework which, if eliminated, would mean
pressure throughout the system could be
further reduced.
Boosting efficiencies
The customer accepted ERIKS’
recommendations, and the pipework
system was modified. At the same time,
a variable speed booster set was supplied
as the most cost-effective replacement for
the existing pumps.
The booster set significantly improved the
system, helping it to provide more consistent
pressure with increased efficiency, and
reduced power consumption.
In both these cases, ERIKS know-how
helped to identify positive energy-use
reductions and cost savings above and
beyond the customers’ expectations.
Having the expertise to get to the
root cause of the problems, and the
solution-neutral capabilities to offer
the most effective solutions for the
customers’ needs, meant significant
performance-, energy- and cost-
efficiencies.
SEARCHING
FOR CLOSURE
You and the

The Rexnord solution
Having studied the customer’s
requirements, ERIKS identified a coupling
from the Rexnord®
Thomas®
XTSR range,
which offered the perfect solution.
n Rexnord Thomas XTSR71 coupling
n Size: 1298
n DBSE: 175mm and 180mm
(two supplied)
n ATEX II 2GD c T6 compliant
n API610 compliant
n IS014691 certified
n Spark reduction construction
PumpCouplingMotor
FORGET MARRIAGE GUIDANCE. THE KIND OF COUPLE COUNSELLING
OFFERED BY THE ERIKS CENTRE OF EXCELLENCE FOR COUPLINGS MAKES
SURE THAT ANYTHING BROUGHT TOGETHER, STAYS TOGETHER – INCLUDING
ERIKS AND REXNORD, THEIR COUPLING SUPPLIER PARTNER.
Supporting the supporters
The ERIKS Centre of Excellence for
couplings and drives is staffed by a highly
experienced team.
But as well as bringing their own industry
experience to bear on the problem, the team
have been specially trained by application
engineers from their supplier partner:
coupling manufacturer and process and
motion control specialist, Rexnord®
. This
gives them exceptional capabilities in solving
coupling and drives problems of all types,
across all industries and applications. And
this particular problem was no exception.
The team brought their know-how and
passion for technology to bear, and provided
the Service Centre with an improved solution
to offer the customer.
Upping the ante
ERIKS’ expertise and experience, broad
range of suppliers, and solution-neutral
approach means the product and solution
proposed is always the one that’s best for
the customer, not just for ERIKS.
In this case, a close look at the specification
led the Centre of Excellence to suggest
a more up-to-date, higher specification
Rexnord unit [see box-out], which offered
a number of advantages.
The Rexnord Thomas®
XTSR71 is the
latest update to the well-known Series 71
of all-metal, torsionally stiff, disc couplings.
And it’s a coupling which, when operating
within its design parameters, is designed
for infinite life.
More than a couple
The new coupling provided the customer
with numerous benefits compared to their
original specification.
The Rexnord Thomas
XTSR71 is smaller
than the original
coupling, which
means it also costs
less. And being lighter,
it puts less strain on the
bearings in the drive – helping
to extend their service life –
and reduces the overall power
consumption needed to drive
the pump assembly.
Compliant with ATEX II 2GD c T6, the
coupling is not only approved for Gas and
Dust explosive atmospheres, but also for
T6: the toughest temperature class for
the group and category. In addition, it is
constructed using Monel (copper-nickel
alloy) bushes, which offer a high-level
of spark reduction.
The design of the XTSR71 has been
optimised to reduce the coupling’s mass
and increase bore capacities. It also provides
component modularity, together with
integrated rigidising for balancing,
and improved corrosion protection.
Easy to own
With the new coupling installed, the
customer has discovered a number of
other advantages and benefits which
make it an easy product to own and run:
1. When replacement of the Centre
Member Assembly (CMA) is required,
the unit can simply be “dropped out” of
the pre-assembled part and replaced.
This means there’s no need to set-up
the pump and motor alignment each
time the coupling is serviced.
2. The flexible nature of the coupling
means it can accommodate a certain
amount of misalignment between the
pump and electric motor, which helps
to protect the bearings and prolong the
life of the whole system.
3. The coupling’s modular construction
means the CMA can be kept as a
separate spare part, enabling very
quick replacement.
ERIKS ultimately supplied the customer
with two units. One has a 175mm, and the
other a 180mm, DBSE. All service parts –
common to both couplings – have also been
supplied, comprising hubs, disc packs,
adaptors, and nuts, bolts and washers.
By providing a coupling with a high-
efficiency design, easier maintenance
and infinite-life design, the ERIKS Centre
of Excellence has given the customer a
comprehensive solution which meets all
their needs – and for a lower purchase
price than they expected.
In other words, the perfect marriage of
efficiency and cost-effectiveness.
COUPLECOUNSELLING
When a very large, international
petrochemical company had coupling
problems, they turned to ERIKS’ Grimsby
Service Centre for guidance. They called
on the expertise of the couplings Centre
of Excellence, to ensure a quick, cost-
effective solution.
Refining the answer
The petrochemical company needed a
coupling to fit between a motor and pump
on one of the many pump drives at their
refinery. This type of “spacer” coupling is
used in all petrochemical process plants,
on the majority of their pump drives.
The location and application meant it had
to be not only API610 (American Petroleum
Institute standard) compliant, but also ATEX
approved and non-sparking. When they
contacted ERIKS, the customer suggested
a possible unit and also provided a detailed
specification, including hub and bore sizes
and Distance Between Shaft Ends (DBSE)
dimensions.
Rather than simply and blindly following
the instructions, the Grimsby Service Centre
contacted the Centre of Excellence, for
expert advice both on the specification
and the suitability of the unit the customer
had suggested.
The know-how and expertise of the team
at the Centre of Excellence meant they
could propose a solution that was better
in more ways than one.

WHICH ARE MORE ENERGY-EFFICIENT – ELECTRICAL OR PNEUMATIC COMPONENTS?
WHAT ADVANTAGES DOES ONE TECHNOLOGY HAVE OVER THE OTHER? MANY EXPERTS
BELIEVE THAT THE IDEAL SOLUTION IS A COMBINATION OF BOTH. HOWEVER, THIS
IS A SITUATION WHERE PREJUDICES OFTEN PREVAIL OVER FACTS. A COMPARISON
IS THE IDEAL WAY TO ENSURE CLARITY.
Energy efficiency depends on the application.
“This must be clearly defined before a user
chooses the drive technology – electric or
pneumatic or a mixture of both,” explains
Roland Volk, energy efficiency consultant at
Festo. But what does this mean in concrete
terms? Only a direct comparison of two
identically sized drives – one electric and one
pneumatic – is able to clearly show the
benefits of each technology. In our
comparison, motions are performed from
point A to point B. This results in very different
energy consumption values.
Task 1: Moving and holding
In the case of motion without additional
process force, an electric drive consumes
only one-third (25 Ws) of the energy that a
pneumatic actuator needs (78 Ws). For the
function ‘pressing with process force’, both
drives roughly consume the same amount
of energy, i.e. between 20 and 30 Ws. If,
however, the drives are required to hold a
certain position, the energy consumption of
the electric drive shoots up to 247 Ws. This
is more than 22 times as much as the energy
consumption of the pneumatic drive (11 Ws).
The pneumatic drive benefits from the fact
that it requires energy only for the brief
moment in which pressure is built up. The
holding process itself can be carried out
completely without any fresh compressed
air supply and there are thus no energy
costs. The electric drive, on the other hand,
requires electricity constantly in order to
remain in the desired position. The longer
the holding process, the higher the energy
consumption of the electric drive compared
to the pneumatic one.
Task 2: Gripping
A comparison of electric and pneumatic
grippers produces similar results. The
comparison shows how finding the right
solution depends on a clear definition of
the application. If we consider the energy
consumption during the gripping process, a
pneumatic gripper is superior to an electric
gripper in applications with long cycles and
with few gripping operations. A pneumatic
gripper requires pressure only once for
continuous holding. After that, no more
pneumatic energy is required for the duration
of the holding operation. An electric gripper,
which needs electrical energy for the entire
holding operation, can be more energy
efficient than a pneumatic gripper only if the
application consists of short cycles with a
large number of gripping operations.
The application decides
The benefits of electrical components are
particularly evident in motion tasks involving
high speeds and long stroke lengths. Electric
drive technology is generally used more
energy efficiently when the requirements
are for flexible positioning, variable motion
profiles or high speeds. If, on the other hand,
simple, robust handling or high power density
is important, pneumatic drive technology
offers numerous advantages.
The Total Cost of Ownership should
also be taken into account when deciding
which drive system to use. Pneumatic
drive systems are between 8 and 10 times
cheaper to purchase than electric drive
systems. Depending on the stroke length
and cycle time, the operating costs may
be higher than those for electric drives.
However, amortisation times of more than
ten years are certainly possible.
Energy efficiency pays off
Energy consumption in production is
influenced by factors other than the
choice between pneumatic and electrical
technology. Users can obtain concrete
results using the Festo model calculator.
For example, a company with a three-shift
operation and a compressor output of 160
kilowatts can reduce its operating costs by
16% simply by using vacuum generators
that operate according to the venturi
principle and have an integrated air-
saving circuit.
www.festo.com/energy_calculator
The secret is in the mix: The most
energy-efficient solution will often be a
combination of electric and pneumatic
drive technology, as in the case of many
of the ready-to-install handling systems
from Festo.
THE RIGHT
CH ICE
Roland Volk
Innovation and Technology
Management at Festo
1
5
9
2
6
10
3
7
11
4
8
12
Energy efficiency measures
1 Reducing pressure level 2 Reducing pressure drops 3 Reducing flow rate
4 Correct sizing 5 Reducing energy consumption 6 Reducing leakages
7 Reducing weight 8 Reducing tubing length 9 Recovering energy
10 Air-saving circuits 11 Reducing friction 12 Switching off power
3
festo.com/energysaving
festo.com/energyefficiency

THE SEVEN
DEADLY WASTES
IF YOU – LIKE MANY BUSINESSES – ARE STRIVING TO
REDUCE OPERATIONAL COSTS, PERHAPS TIM WOOD
CAN HELP. BUT THAT’S NOT A PERSON; IT’S A WAY OF
REMEMBERING THE SEVEN DEADLY WASTES YOU
NEED TO DEAL WITH.
In most of the Lean business principles
you may already be adopting – like Lean Six
Sigma, the Visual Workplace, the Five S’s and
Kaizen – a key principle is to reduce waste.
And the seven most common areas of waste
are Transportation, Inventory, Movement,
Waiting, Over Production, Over Processing
and Defects or TIMWOOD, for short.
With over 50 years’ experience across
numerous industries, SMC can help you not
only address TIMWOOD and reduce waste,
but also add value, simply by looking at one of
the easiest areas for action: compressed air.
Where’s your air going?
The first steps towards saving waste
with compressed air can be made in your
compressor room. Here you can identify:
n what type of compressors you have
n how they’re run and
n how compressed air is used on site.
After all, there’s little point upgrading your
compressor room if all you’re doing is more
efficiently feeding the compressed air
inadequacies across your business.
You can support Lean principles such
as Total Preventative Maintenance,
by monitoring your compressed air usage
and what’s going on in the compressor
room, on the ring main and at machine
level. Once compressed air gets out into
the factory, usage monitoring is lost, which
can be an issue when department budgets
are set without knowing current actual
performance.
Simple two-colour digital air flow monitoring
sensors can be fitted in the ring main or at
machine level and fit in perfectly with the
Visual Workshop key principle of Lean –
allowing operators to spot issues quickly,
either in line or at machine level – additional
digital or analogue outputs allow data to be
captured and monitored in real time by
control systems.
One recent innovation; Automatic Leak
Detection Systems (ALDS), fitted to
machinery during the build stage can also
help to drive down energy costs. These
systems show in real time where a machine
is suffering from compressed air loss, so
the maintenance team can decide whether
a repair is needed immediately or at the
next maintenance interval.
More ways to save
Something as apparently simple as air offers
a surprisingly large number of different ways
to save money.
For example, vacuum systems are often
ignored when looking for compressed
air savings. Unless you have a vacuum
pump running, a vacuum generator uses
compressed air to generate a vacuum using
the Venturi principle. This can be inefficient
and expensive, as a vacuum generator may
continue to consume compressed air even
after the product is gripped.
However, the latest vacuum generators shut
off as soon as a vacuum is made, saving up
to 90% on compressed air consumption.
Air blowing – typically used for cooling,
drying, moving, orientating and rejection of
a product – is another area where energy
savings can easily be made. Continuous
air blow through a simple tube can cost
over £2k a year, but optimising air blow
equipment to the application can reduce
costs considerably.
As energy consumption is part of your
sustainability drive you may be interested
to know that there are now alternative
technologies to stop pneumatic filtration
products going to waste in landfill sites,
or help you meet a CSR “ Zero Landfill”
commitment. Although single-use bag
filters are common in manufacturing,
unique alternatives including “wobble plate”
filtration system for fluids, with a reusable
filter element eliminate the need for bag
filters, and saves on landfill.
Saving the best saving until last
For the biggest tangible saving in
compressed air usage, all that’s required
is to make sure you’re using the correct
pressure setting for your application.
Reducing output pressure by just 1 bar can
save around 7% of the electricity cost used
to generate the compressed air.
However, it’s essential to carry out
all necessary preparation work before
turning down line pressure. If you have
failed to adopt basic good practice –
such as fixing known air leaks, reducing
pressure drops, and optimising vacuum
and blow-off systems – machines may not
operate correctly with reduced pressure.
If some equipment needs higher pressure in
comparison to other applications, consider
a point-of-use air booster removing the
need for a whole network to run at an
elevated pressure.
Choose to save
When you adopt Lean principles, it’s not just
the cost of buying a product that you should
consider. Only around 15% of the purchase
price is reflected in a product’s Total Cost of
Ownership (TCO), so you also need to look
at the cost of energy to run the equipment,
as well as warranty and procurement
expenses. There are a number of online
selectors that can help with this along
with advice from technical specialists
from ERIKS and SMC, good advice
pays dividends.
John Turner
Industries Development
Manager at SMC
SMC products that cut your energy costs
SMC’s two-colour digital air flow monitoring
sensors can be fitted in the ring main or at
machine level, to measure flow rates from
0.5 l/m up to 12,000 l/m. The two-colour
digital display and the digital and analogue
outputs allow data to be captured and
monitored in real time.
Automatic Leak Detection System (ALDS)
installed at the build stage helps minimise
energy costs.
The highly efficient SMC ZK2 vacuum
generator can save up to 90% on
compressed air consumption.
To optimise air blow efficiency, an SMC KN
Blow Nozzle, VMG Blow Gun or ZH Air
Amplifier Unit can reduce costs
considerably.
The SMC unique “wobble
plate” filtration system for
fluids, with a reusable filter
element eliminates the need
for bag filters.
If some equipment needs higher pressure in
comparison to other applications, an SMC
series VBA point-of-use air booster could
be installed.
To make this easier, SMC has a range of
product selection software tools to help
you select the most cost-effective and
energy-efficient products available.
Just visit www.smcpneumatics.co.uk
to start choosing, start saving, and start
achieving your compressed air KPIs.
Cheaper than air?
Sometimes the simplicity of compressed
air is not available, and sometimes it’s
seen as less cost-effective to use than
other methods. For both these situations,
SMC has developed an extensive range
of stepper and servo motor actuators,
including linear, rotary and gripper
drive models.
These simple SMC controllers for the
stepper drives units even allows non-
technical staff to set-up and commission
the actuator – freeing technical engineers
to concentrate on more challenging issues.

THE NEED FOR INDUSTRY TO REDUCE ENERGY USE IS NOT GOING AWAY
ANY TIME SOON. TWO POSSIBLE SOLUTIONS, AS ROB JENKINSON, DIRECTOR
CORPORATE SUSTAINABILITY FROM SKF EXPLAINS, ARE THE BEARINGS THAT
REDUCE FRICTION IN ELECTRIC MOTORS AND MOVING FROM TRADITIONAL
HYDRAULIC OR PNEUMATIC ACTUATION TO ELECTRO-MECHANICAL LINEAR DRIVES.
Automating
energy-saving
As industrial processes
have become increasingly
automated, as part of the
push to improve energy
efficiency, linear drive technology
has come under intense scrutiny.
Traditionally, most linear drive systems
have been pneumatically or hydraulically
driven. But in many applications, electro-
mechanical systems are beginning to
replace them.
Pneumatic and hydraulic systems do still
offer a number of advantages – depending
on the specifics of the application and the
operating environment – but electric cylinders:
n require less ancillary equipment
n are cleaner
n are more reliable
n demand less machine downtime
for cleaning and maintenance and,
most importantly
n are more energy efficient.
Hydraulic systems typically require around
40% more energy than electric cylinders,
while pneumatic systems may require up
to 90% more energy due to the inherent
inefficiency’s in these systems. This is
due to the energy losses inherent in
compressed air systems such as the
rejected heat, piping losses, the leaks etc.
Likewise in hydraulic systems – converting
from electrical energy to pressurised
hydraulic fluid energy incurs losses which
are avoided with the direct mechanical link
from the motor to the actuation rod in an
electromechanical actuator.
Facts about friction
Electric motors are an energy expensive
component. They consume a total of
approximately 1.36 trillion KwH per year in
the EU and USA alone, so increasing their
efficiency represents a massive opportunity
for industry.
One way to do this is to reduce friction.
Reducing friction in the rolling bearings
used in motors will reduce the amount
of energy required by the motor itself.
Specially-engineered rolling bearings
can significantly lower friction, resulting in
impressive energy savings. Lower friction
also means the bearings run cooler than
a basic-design bearing, which extends
bearing life due to the improved lubrication
properties at lower temperatures.
Good for business and the planet
Reducing energy use – which in turn can
decrease greenhouse gas emissions – and
minimising air and water pollution, can all
deliver cost benefits in the short term, by
reducing running and maintenance costs.
In the long term, emphasising green
credentials to customers and potential
customers can only help to win business
and increase customer loyalty.
In the even longer term, saving energy helps
to reduce emissions and that’s not just good
for business – it’s good for the planet too.
SKF BeyondZero
In 2005, SKF launched a new strategy for
reducing environmental impacts, called SKF
BeyondZero. The strategy drives actions to
reduce the impacts of SKF suppliers as well
as SKF’s own operations (reducing the
negative impacts), while in parallel developing
solutions with our customers that help them
do the same (increasing the positive impacts).
The SKF BeyondZero portfolio spans SKF’s
five platforms of bearings and units, seals,
lubrication systems, mechatronics, and
services, across every industry in which the
company is present. To be included in the
portfolio, a solution must deliver or enable
significant environmental performance
improvements.
Two examples of products within the SKF
BeyondZero portfolio with wide-ranging
applications in any manufacturing business
are SKF CASM electric cylinders, and SKF
Energy Efficient bearings.
SKF CASM – an electromechanical solution
for linear drives – can provide energy savings
of up to 90% compared with pneumatic
systems* – resulting in important cost savings
and reductions in environmental impacts.
SKF Energy Efficient (E2) performance-class
bearings also offer dramatic improvements
over other options. Specially engineered and
manufactured to reduce frictional moment by
30% or more beyond SKF’s already efficient
standard bearings, the reductions can be
even more dramatic when compared with
other manufacturers’ bearings.
Available in a wide variety of bearing types,
SKF E2 bearings run 5-30°C cooler than
SKF basic design bearings, depending on
operating conditions. SKF E2 Y-bearings
have been designed for applications in which
reduced energy usage is an important
concern. Under normal operating conditions,
they also have a considerably longer grease
service life than a standard SKF Y-bearing,
helping to reduce lubricant consumption.
* Swiss Federal Office for Energy
As energy awareness
evolves, matures, and
combines with
increasing
environmental
consciousness,
more businesses
are realising that
energy use reduction
can be about being
green as well as staying out of the red. As
we are all becoming more environmentally
conscious, manufacturing industry seeks ways
to make their activities greener to match our
expectations as consumers. On top of this,
there are increasing regulatory requirements
on businesses – in the UK for example - the
Carbon Reduction Commitment (CRC) to the
Energy Savings and Opportunity Scheme
(ESOS).
As a result, reducing the amount of energy
used, increasing the energy efficiency of
applications and components, and therefore
reducing their carbon footprint, is now a top
priority for many businesses.
Some more forward-looking businesses are
going further still, taking action not simply to
reduce the negative impacts of their own
operations, but to accentuate the positive
by putting a focus on developing products
and solutions which help their customers
by providing or enabling significant
environmental performance improvements.
In other words, reducing or eliminating your
own operational negative environmental
impact is only the first stage. Delivering
positive environmental benefits to your
customers is an even more effective
second stage.
Rob Jenkinson
Director, Corporate
Sustainability at SKF
ENVIRONMENTAL
IMPACTS
BEYOND
ZERO
GOING
ON

The most widely used method of extraction
involves large exhaust air systems to remove
the air, with high-tech membrane filter systems
to remove the mixture of aerosols and paint
from the air first. This incurs high costs not
only for supplying the clean air, but also for
the downtime and labour involved in
cleaning the filters.
Now a new solution eliminates downtime
and reduces associated costs too.
Non-stop cleaning
The new RECLAIM process from Keller
Lufttechnik uses a new type of filter, which
can regenerate during operation – so there’s
no need to stop the painting process. And it
saves energy too.
The system works by using fabric filters
pre-coated with PTFE, and an auxiliary filter
layer of limestone powder. The limestone
powder absorbs and bonds with the
adhesive aerosols of the overspray, to
prevent the filter clogging up and quickly
becoming unusable.
However, the system also goes further
to save energy, time and costs.
Weight sensors located under the dust silo
detect the degree to which the pre-coating
material is saturated with overspray. As long
as a pre-defined total weight – consisting of
pre-coating and powder – is not exceeded,
the mixture previously blown off the filter
plates can be blown back on.
When it resettles on the filter the limestone
powder and paint overspray mixture forms
a new auxiliary filter layer. This continues
until the weight exceeds the pre-defined
limit, at which point the overspray-saturated
limestone powder is removed from the
system, and new limestone powder added.
And all this takes place automatically, with
no downtime required in painting operations.
Energy-saving air
This innovative technology cleans the air so
effectively that up to 95% of the extracted
dirty gas can be returned to the paint booth
as pre-conditioned clean gas – saving
significant amounts of energy.
In fact, compared with paint booths without
this technology, energy costs are reduced
by as much as 50%.
If a paint booth requires 1,000 cubic metres
of air per hour, which has to be supplied
from the outside and heated, it uses around
60 megawatts of energy per annum. Assuming
a suction rate of 16,000 cubic metres per
hour, if the amount of air supplied from
the outside can be reduced to just 5% –
instead of the usual 100% – then savings
of over £40,000 can be made every year.
Painting green and black
By reducing energy use, the new air filtering
technology for paint booths contributes to a
more ecologically-friendly painting process.
At the same time, it helps to significantly
reduce costs for the operator – helping to
maintain a healthier bottom line as well as
a healthier planet.
INDUSTRIAL PAINTING INEVITABLY PRODUCES LARGE AMOUNTS OF OVERSPRAY.
THIS CONTAMINATES THE AIR OF THE PAINT BOOTH, BUT CAN’T BE RELEASED
INTO THE ENVIRONMENT. SO THE AIR HAS TO BE EXTRACTED, CLEANED, AND
REPLACED WITH FRESH, CLEAN AIR. IT’S AN ENERGY-INTENSIVE PROCESS AND
A COSTLY ONE TOO. BUT NEW AIR TECHNOLOGY HAS BEEN DEVELOPED TO
SOLVE THE PROBLEM.
LET US
AND SAVE ENERGY
Complete control from Festo
A sophisticated automation solution such as
Keller Lefttechnik’s new RECLAIM process
demands an equally sophisticated control
system. A key component in this is the
CPX-VTSA valve terminal from Festo, which
combines a modular electrical terminal (CPX)
with a valve terminal (VTSA).
Previously, similar systems have used 2/2-way
individual valves, which have lacked a complex
monitoring and control function. However, the
CPX-VTSA now provides this, to guarantee a
smooth process at all times.
Valve choice
The flow rate of systems of various sizes
is regulated by Keller Lufttechnik simply by
choosing valves of different sizes on the valve
terminal. The individual valves are then precisely
adjusted to the required flow rate, using
pressure regulator plates.
At the same time, the CPX modular electrical
terminal controls all the electric actuators and
sensors in the system, via ProfiNet bus nodes.
The VTSA pneumatic interface provides the
electromechanical connection between the CPX
terminal and VTSA valve terminal. A complete
pneumatic control chain is connected to the
fieldbus using the input modules of the
CPX terminal.
Extended service intervals
The CPX-VTSA controls the pressure
regulators for adjusting the pressures and
flow rates in the RECLAIM system, as well
as controlling vacuum exhausting of the pinch
valves. This optimises transport parameters,
and helps to extend service intervals.
In addition, peak load regulation stabilises the
compressed air system; active consumption
rate monitoring helps to reduce compressed
air consumption values; and there is actuation
of exhaust-free fluidisation valves without raw
gas return flow.
To find out more, visit
festo.com/catalog/vtsa

This month’s debate This month’s debate
DECIDING WHETHER TO REPAIR OR REPLACE A PUMP
IS RARELY A BLACK AND WHITE ISSUE. ANDY CRUSE,
FROM ERIKS PUMP DIVISION, DEFINES THE KEY
DECISION MAKING CRITERIA FOR PUMP USERS
AND OFFERS HIS VERDICT ON THE REPAIR OR
REPLACE DILEMMA.
CRITERIA #1 Cost
In the end most things come down to cost. If the unit price for a new
pump is relatively low and is available it can make economic sense to
replace. Our view is that single stage pumps up to 15kW, used in light
industrial and HVAC, are replace rather than repair, because the cost
of repairing failed bearings and seals, for example, is uneconomic
for the pump user. For larger and “engineered” pumps it’s a different
case altogether. This type of pump is of a more substantial build
quality and will lend itself well to a number of maintenance and
repair regimes over it’s working life, which is reflected in the price.
At this point repair makes much more sense.
THE VERDICT
Repair: if you’re using larger or “engineered” products where
the main components are cast rather than pressed fabrications.
Replace: if your pump is in the “up to 15kW” range and the unit
cost of a new pump is relatively low and readily available.
CRITERIA #2 Production disruption
Arguably the key criteria for pump users in industry. I know of one
pump user who accepted the fact that his pump would only have
an operational life of circa six weeks and always kept a spare on
hand to quickly plug in and keep production going. It’s not an option
I’d recommend, because pump operational life can be subject to
multiple variables not just the pump itself, but if repair is too costly
in terms of downtime, then it is one way of keeping going.
THE VERDICT
Repair: if the pump is in a non-critical production area or a stand-by
pump can be quickly brought online.
Replace: if the pump is critical to production operations and there
is no alternative pump available.
CRITERIA #3 Energy efficiency
The European Union has been the driving force behind some very
significant improvements in pump efficiency in recent years, which
has added another criteria to the pump decision making process.
The ErP Directive, for example, enforced a Minimum Efficiency
Index which identified minimum hydraulic efficiency that all
manufacturers must meet, dramatically increasing pump efficiency.
A modern end suction pump, for example, is circa 13% more
efficient than its predecessors. Pump users need to be calculating
how much energy it is possible to save, along with potential payback
periods, by upgrading their pumping technology, before making a
repair or replace decision.
THE VERDICT
Repair: if your pump is modern, high efficiency and ErP compliant.
Replace: if you are using old, inefficient pumping technology.
CRITERIA #4 Plant room disruption
Another big issue for pump users. It’s all very well saying it’s easier
to replace a pump rather than repair, but much of the existing pump
equipment, already in use, has configurations and dimensions bespoke
to the manufacturer and not to a recognised international standard.
This can mean that direct replacement is nigh on impossible in
some cases. What’s more, old plant rooms often have asbestos
lagging around pipework which pump users are reluctant to disturb.
THE VERDICT
Repair: if it’s old plant with outdated dimensions and standards
and where there is potential for significant disruption and budget
constraints, there may well still be savings opportunities to take
benefit from thorough modern motor control regimes.
Replace: if it is a modern plant manufactured to international
standards offering an easy like-for-like swap.
CRITERIA #5 New pump availability
A criteria that is very much dependent on the pump and its application.
For smaller up to 15kW pumps, both manufacturers and distributors
keep plenty of ex-stock available on the most popular sizes, which
can usually be shipped in 48 hours. Bespoke pumps for process
applications with special options, such as seal and material variants,
are a different matter entirely, because they are not as readily
available and often are subject to long lead times.
THE VERDICT
Repair: if the pump is specialist or bespoke and has a long lead time.
Replace: if stock is readily available and can be accessed within
a short timeframe.
CRITERIA #6 Spares availability
Ready access to spares is a key criteria in assessing whether
to repair or replace. For water pumps in light industrial or HVAC,
all-too-often the cost of the part, labour and downtime means that
any repair or replace calculation comes out on the side of replacement.
Process and wastewater pumps are a different case, with manufacturers
often making ‘repair kits’ available which have a variety of components
that are prone to wear. Obsolescence is another issue. There are plenty
of pumps still in the field that are more than 30 years old and which
are no longer supported by the original OEM or, alternatively, the cost
of spare parts is increasing year-on-year. Pump users need to assess
whether continuing with these pumps poses a risk to their operations.
THE VERDICT
Repair: if spares and repair kits are readily available or can
be reverse engineered.
Replace: if the pump is designed for replacement rather than
repair and the cost, including parts, labour and downtime, make
repair uneconomic.
CONCLUSION
Pump repair or replace is not an easy decision, but whilst cost and potential disruption to production are the key criteria, other factors,
such as plant room disruption, can lead a pump user coming to the conclusion that, despite increasing spares costs and all the potential
for energy saving, there really is no alternative to soldiering on with their current pumps. My advice is to get advice. Often what seems
like a pump problem is actually a system issue which the pump is getting the blame for. The only real way to get the best out of your
pumps is to step back a moment, assess what the pump is actually being used and whether it is fit-for-purpose, before making
informed long-term and strategic decisions.
For more information on ERIKS please visit: www.eriks.co.uk
REPA R OR REPLACE:
THE KEY CRITERIA
FOR PUMP DECISION-MAKERS
Andy Cruse
ERIKS Pump Division

Time savings Time savings
26 27ISSUE 23 knowhow.eriks.co.uk
The dairy manufacturer had been asked
by a number of customers to provide milk
packaged on pallets for onward distribution,
rather than in delivery cages as they
normally did.
Although the production site had no
palletising facility, the manufacturer was
interested in testing-out palletised delivery.
So they decided to investigate adapting a
small number of existing lines as a small-
scale trial.
Starting small
An in-house project team was assembled
to undertake the task, and came up with
a plan.
Their idea was to initially adapt two existing
conveyors to enable the palletisation. This
would involve adding an extra five metres
of conveyor to transport the product into
the chill area, where it could be manually
stacked onto pallets by a team of people.
The product could then be pallet-trucked
away to automatic rotary arm pallet wrappers.
If this trial system proved successful, and
demand volume increased, then a fully
automated version would be considered.
So far, so simple.
Hitting the belt - and hitting problems
Unfortunately, the project team’s proposal for
belt conveyors attached to a roller conveyor
was not a suitable solution. When the product
hit the belt it would have fallen over.
Even more frustratingly, getting the capital
expenditure agreed for the project took
longer than expected, which meant a schedule
too tight for the conveyor manufacturer to
meet – fatally compromising the required
delivery deadline.
For the dairy manufacturer, it was all
turning sour.
Getting the cream
With time pressing and no viable solution
in sight, it was time to call in ERIKS.
The local ERIKS MRO Specialist quickly
put a plan in place which would provide a
product solution to the customer’s exact
specifications, and meet the customer’s
packaging demands. It could also be
guaranteed to be delivered on time, thanks
to ERIKS’ know-how, and extensive network
of trusted, reliable, and high-quality supply
partners: the crème de la crème.
Working with one of these – an existing
conveyor partner – ERIKS committed to
project-manage the design and build of the
required conveyors with just a three-week
lead time.
All wrapped up
With the initial fabrication underway, the
customer decided to add an extra metre
to each conveyor. This meant more parts
needed ordering against an even tighter
delivery window, but ERIKS’ close relationship
with the conveyor manufacturer meant the
original agreed deadline was still adhered to.
Meanwhile, in addition to the conveyors,
two pallet wrappers were required to
shrink-wrap the loaded pallets of product.
The customer’s original plan had been to
use a type of pallet wrapper with a moving
platform for the pallet to sit on as it’s
wrapped. However, ERIKS’ engineers
pointed out that this was an unsuitable
option for an inherently unstable product.
As an alternative, ERIKS suggested the
use of rotary arm pallet wrappers. These
work on the opposite principle: moving the
wrapper around a static pallet, so there’s no
risk of the product falling over. The customer
agreed to this solution, and ERIKS’ engineers
began working in collaboration with an
European supplier, to ensure manufacture
and delivery of the correct specification
equipment to the required two- to three-
week lead time.
Know-how, in pints
What made life harder for the dairy
manufacturer’s own project team of
engineers was the need to juggle an
urgent one-off project with the demands
of keeping a busy production facility
up and running.
ERIKS’ engineers have the advantage not
only of unparalleled technical know-how, but
also of being able to dedicate a team to a
project. This means solutions can be arrived
at more quickly, and also releases a customer’s
own engineers to concentrate on what they
do best. Of course, it remains a partnership,
but one where ERIKS can take the
pressure off, while the customer can
still take the decisions.
In this case, the dairy products manufacturer
benefited in two ways.
Firstly: saving the valuable time of their
engineers by taking the bulk of the project
off their hands. Secondly: saving time on
the entire project timescale, by achieving
a solution which was designed right, built
right, and delivered and installed with a
short lead time, right on time. Calling in
some additional know-how can save
significant amounts of time!
IN-HOUSE EXPERTISE CAN OFTEN SEEM LIKE THE EASIEST AND MOST COST-
EFFECTIVE WAY TO GET A JOB DONE. BUT AS A LARGE DAIRY MANUFACTURER
DISCOVERED, SOMETIMES THERE’S NO SUBSTITUTE FOR A PARTNER WITH
TECHNICAL KNOW-HOW, INDUSTRY UNDERSTANDING AND CLOSE RELATIONSHIPS
WITH CRUCIAL SUPPLIERS – NOT JUST TO COMPLETE A PROJECT, BUT TO
COMPLETE IT ON TIME.
Rotary Arm Pallet
Wrapper - courtesy
of Mima-Films.

Best practice Best practice
ALL TOO OFTEN, A DECISION IS MADE TO CARRY OUT
AN IN-HOUSE REPAIR TO A PROCESS GEARBOX IN THE
BELIEF IT WILL SAVE MONEY. THE REALITY IS OFTEN
VERY DIFFERENT.
Simon Whitehouse
Business Unit Manager
Gearbox Repairs
Long lead times, difficult modifications or
higher initial costs can all make replacing or
upgrading look less attractive than repair.
But problems arise, and costs rise, when you
choose in-house repairs rather than
sub-contracting to a third party.
Because there’s not just one cost to
consider, but four:
1. Lost production
2. Removing the equipment from the line
or process, and subsequently replacing it
3. The actual repair
4. In-house engineers making repairs, so
being unavailable to tend to other parts
of the plant (opportunity cost).
Taking any or all of these into account
means the longer that plant can run
between maintenance intervals, the less the
total downtime cost per year of production.
And when your gearbox repairs are
entrusted to an expert refurbishment house,
then the life of the refurbished gearbox will
almost certainly be extended and that total
cost reduced.
As good as new?
To fully realise the benefits of sub-
contracting, it’s essential the repair is carried
out to a high standard.
In fact, nothing less will do than a gearbox
rebuilt to precise manufacturers’
specifications, backed by fully-guaranteed
workmanship. This means finding a repairer
with the experience and know-how to
rebuild industrial gearboxes of all leading
types and styles, and able to guarantee the
use of only genuine manufacturers’ parts.
The repairer you choose should also offer a
comprehensive, lengthy guarantee – and
ensure the gearbox is fully tested before it’s
returned to you.
It’s your choice
Whether to repair or replace is, of course,
ultimately your decision alone, based on the
economic viability for your business. But to
help you decide, a reputable repairer will
always carry out a full engineer’s inspection
and provide you with a written assessment
before any work is begun.
This not only provides reassurance that you
are right in your assessment of the problem,
but also acts as a restraint against more
work being done – and charged for – than is
strictly necessary. And if you choose a
repairer who can also offer a full range of
replacement gearboxes, then you can
expect unbiased, solution-neutral advice.
The overhaul alternative
Another option for your gearbox is
reconditioning and overhaul. Some repairers
offer this service, and some can even rebuild
obsolete designs to meet the manufacturer’s
original specifications.
The scope of the work – and therefore of
the repairer’s competence – may include:
n replacement of worn or broken
- gears
- bearings
- seals
- shafts
n uprating and modifying designs to suit
specialist applications.
The gearbox should then be reassembled
and returned in “as new” condition.
Again, prior to any work taking place, the
unit should be stripped, examined and
written-up in a detailed report for your
approval.
ERIKS’ Core Competence Centre
(CCC) – Gearbox Maintenance
and Repairs.
A refurbishment specialist with close
relationships with process gearbox
manufacturers, and many years of
experience and know-how. Providing a
dedicated, 24-hour, quick-response
gearbox rebuilding and complete gearbox
service unit.
ERIKS’ repairs and rebuilds using only
genuine parts from manufacturers such as:
n David Brown
n Fenner
n Renold
n SEW
n Flender
n and many others.
Gearboxes are returned fully repaired,
serviced and tested, within days as
standard, or even on the same day if
required (all subject to work requirements
and inspection). Every fully-overhauled
gearbox carries a twelve-month guarantee.
If you decide a repair is uneconomical,
ERIKS CCC Drives facility in the West
Midlands carries an extensive range of
replacement drive products, and can
quickly access more from an extensive
supplier base. ERIKS can also supply
purpose-made gearboxes, complete drive
installations or open drives, or simply
uprate an existing gearbox.

30
The Tig
Art on an
industrial
scale
“In my lounge at home I have a
signed limited edition print of a
Trevor Grimshaw pencil drawing called
‘Church and Chimneys’ which depicts a
mid-20th Century industrial landscape
in the North of England.
The print is gritty and it divides opinion.
Visitors either love it or hate it. I suspect
those who hate it see an image of industrial
decay. Those who love it see an echo
of their own upbringing or early careers
forged in engineering and manufacturing.
When the print was first published in
1973 one art reviewer commented:
“Where the rest of us turn up our collars
and head for home and tea by the fire,
the artist has stayed for a further look
and found beauty”.
That ‘beauty’ which Grimshaw found in
industrial landscapes has now all but
disappeared. Modern industry is much
more hidden from view. It’s still there,
but now it’s located on out-of-town
industrial estates with carbon copy
business units giving away little of
what is going on inside. The smoke
from chimneys which characterised
much of Grimshaw’s work is now
outlawed by clean air regulations.
50 years ago, our great provincial cities
of Liverpool, Manchester, Birmingham,
Newcastle and Glasgow had skylines
dominated by industrial production, which
brought industry and its economic benefits,
in terms of jobs and wealth creation, much
closer to its people.
Some of these industrial structures were
iconic. The Longbridge car plant conveyor
bridge over the A38 which carried vehicle
bodies from the West Works manufacturing
area to the South plant for paint and
finishing. The cranes of Swan Hunter and
Cammell Laird which dominated the Tyne
and the Mersey. All provided a dramatic
backdrop to everyday life, which artists
like Grimshaw used in their work.
Perhaps this loss of iconic industrial
structures is why so many people think we
don’t manufacture in this country anymore.
The truth is that, although car production at
Longbridge may have disappeared - along
with the A38 conveyor – JLR just down the
road is thriving. More tonnage is moved
through Liverpool now than in its supposed
Victorian ‘heyday’, it’s just that the port itself
has moved down the river to Seaforth to
enable the massive container ships to dock.
Manchester has replaced textiles with
a reputation for advanced engineering.
Sunderland has replaced mining with
Nissan, whilst Derby is building on its rich
railway engineering heritage with its Toyota
plant at Burnaston.
Of course, much of this manufacturing
expertise is now hidden from view, behind
security gates and fencing. Few of us will
ever get the chance to tour the JLR factory
in Solihull or the Airbus facility at Broughton.
The truth is we should not lament the loss
of industry – it’s still there and doing very
well. Rather we should mourn the loss
of the dramatic structures and scenes
which characterised the old industries
and which inspired artists like
Trevor Grimshaw.
“
ISSUE 22 www.eriks.co.uk/knowhow
The modularelectric cylinder system
CASM electric cylinders
Unlike pneumatic or hydraulic cylinders, CASM electric cylinders can be positioned more
precisely, whilst also performing fast and powerful linear movements. And with energy
savings of up to 90%* and a reduced number of components, the whole system is more
cost-effective.
The CASM modular concept enables easy connection to your preferred motor and
control system, and can reduce design and programming costs considerably.
Manufactured with high-grade materials and a sealing system with minimum level
IP54S protection, CASM electric cylinders can be used for extended periods even
under adverse conditions; and together with screws covering different speeds and
forces, they are the optimum solution for a wide variety of applications.
www.skf.co.uk/casm
Source: Swiss Federal Office for Energy*
Siemens servomotors and adapters
Brushless DC motors and adapters
Available with either parallel
or in-line motors
The Power of Knowledge Engineering
® SKF is a registered trademark of the SKF Group © SKF Group 2015
Follow us on:
‘Church and Chimneys’ pencil drawing
by Trevor Grimshaw

PARTNERSHIP BASED ON TRUST –
AND TRUST BASED ON QUALITY
Number One in Total Quality
Products and solutions from NSK are everywhere where things are in motion – even under the toughest conditions. Our high-precision rolling bearings
are used in wind turbines and machine tools, our linear components are found in production lines while our automotive components are installed in
the vehicles of almost every well-known automaker. Our products and services are precisely matched to speciﬁc industrial sectors and segments.
We understand the demands in the principal industries; we know what drives our customers in mechanical engineering.
NSK – one of the world’s leading manufacturers of bearings and linear systems. A premium brand since 1916.
NSK Europe Ltd. · Northern Road · Newark · Nottinghamshire NG24 2JF

ERIKS Know+How Issue 23, Energy Conservation

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