eriks know+how magazine - issue 22

THE LEADING MAGAZINE FOR MAINTENANCE ENGINEERS FROM ERIKS

www.eriks.co.uk/knowhow

ISSUE 22

No surprisesPreventing problems – with Condition Monitoring p28

Talking effluentHow to save with what you waste p12

Save £50,000 on energyThat’s the fine if you don’t meet new legislation p6

Grease is the wordLubricating for performance – and food safety p14

Able cablesFinding the right cable for the job p18

Move along there pleaseHow Rexnord keeps industry moving p20

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Contents

3

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POWER SOLUTION

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ContentsWELCOME TO KNOW+HOW…Covering the latest news, industry developments and technologies, this edition of Know+How focuses on the food and beverage industry and what solutions are available to help maintenance engineers meet the strict hygiene requirements the sector demands.

I look forward to hearing from you.

Alan WhetstoneManaging Director, Editor in Chief

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.

Published by ERIKS UK, Amber Way, Halesowen, West Midlands, B62 8WG

Food and beverage manufacturing has been a mainstay of British industry for generations and is currently enjoying a healthy renaissance. However, navigating the legislative maze which governs the industry puts those who are tasked with powering it under a lot of pressure.

Inside, you’ll be able to hear from organisations that are regularly at the coal face resolving some of the food and beverage industry’s most pressing matters. SKF outlines how lubrication holds the key to the longevity of plant machinery, and will keep potential contamination from maintenance applications to a minimum. Pump manufacturer Grundfos also provides an in-depth look at how embracing new technologies can breathe new life into food and beverage pumping applications.

We are also very pleased to welcome Natasha Wiseman as our guest contributor. Natasha, former editor of both World Water and Water & Wastewater Treatment, will examine the growing impact of water efficiency on both retailers and producers in the food and beverage industry.

As ever, the issue will be rounded off by the TIG, who looks at how poor knowledge of proper maintenance procedures could undermine the current resurgence in British manufacturing.

If you have any comments you would like to raise on the topics contained in this issue you can email the editor at: [email protected] 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 subject and products discussed or contact one of the contributors.

LATEST NEWS 04 Food and drink driving growth in UK manufacturing

UK must boost skills by 2020

Green technologies lead the way in securing innovation funding

Britain on cusp of fourth industrial revolution

IN-DEPTH 06 Energy-saving made mandatory

TECHNOLOGY UPDATE 08 ERIKS launches hygienic duct joint

Fenner adapts to market demand for high performance PT chain

ERIKS targets compressed air inefficiencies

Fast food chain

PLANET PLUS 10 Exciting news on a dry subject

FOCUS ON FOOD AND BEVERAGES 12 Reducing the effluent discharge charge p12

Lubrication: not when, but how p14

When water can kill p17

High-wire act p18

Vital links p20

If it ain’t broke – why fix it? p22

Maximising production efficiencies p24

TIME SAVINGS 26 The savings that didn’t get away

BEST PRACTICE Condtion Monitoring: What, why and how 28

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Latest news Latest news

ISSUE 22 www.eriks.co.uk/knowhow4 5

Food and drink driving growth in UK manufacturing

Britain on cusp of fourth industrial revolutionBRITISH MANUFACTURERS ARE ON THE VERGE OF THE ‘FOURTH INDUSTRIAL

REVOLUTION’, HOWEVER RESEARCH FROM ONE OF THE INDUSTRY’S LEADING

BODIES HAS RAISED CONCERNS OVER BRITAIN’S ABILITY TO PLAY A PIVOTAL ROLE.

EEF, the manufacturers association, has encouraged British companies to brace themselves for the imminent impact of ‘Industry 4.0’ – dubbed the fourth industrial revolution – which has been driven by rapid advancements in technology.

It has estimated that Industry 4.0 will become a widespread reality of manufacturing life within the next ten years, with 80% of manufacturers expecting to be affected by 2025.

Whilst as many as 88% of manufacturers expect the UK to help lead the revolution, 58% also worry that a lack of adequate industrial strategy and support framework could place the UK at risk of falling behind its European counterparts.

Given the socio-economic advantages of being at the forefront of such a movement, the UK is in a precarious position and will continue to be so unless a concerted effort is made to embrace innovation and the technological advances driving Industry 4.0 forward.

Green technologies lead the way in securing innovation funding

UK must boost skills by 2020 to maintain manufacturing renaissance

Forty UK companies have been awarded funding to help research and develop innovative green technologies.

The Energy Catalyst competition, run by Innovate UK, is intended to help support companies committed to solving the energy ‘trilemma’ – namely reducing carbon emissions, increasing supply security and cutting energy cost.

Round One winners include Nyak Technology, who won £200,000 to develop an organic solar cell which could eventually replace domestic windows with transparent energy-producing solar panels. In addition, Oaktec, are currently pioneering the use of untreated gas from landfill sites to power a self-supercharged biogas engine.

Business and energy Minister, Matthew Hancock, said: “The projects we are backing through the Energy Catalyst, demonstrate the depth and breadth of British innovation in the sector. Many of these projects are not only UK firsts, but world firsts, and by supporting them at this early stage, we will ensure the UK reaps the rewards in the future.”

Another £14m of funding was made available in the second round of the competition, which closed in April.

The government must increase its efforts to ensure the majority of UK jobs are medium- or high-skilled by 2020, in order for the British ‘manufacturing renaissance’ to continue.

Led by EEF, the manufacturers’ association, the call pushes for 90% of state secondary school science and maths teachers to have a post A-level qualification in their teaching subject. Similarly, it asks for a 25% increase in the number of manufacturing and engineering apprenticeships.

Under its newly published manifesto titled ‘Securing a manufacturing renaissance: priorities for Government’, EEF also outlines further key steps such as a 25% increase in engineering graduates, and cutting the number of hard-to-fill- manufacturing vacancies by 25%.

Speaking on the launch of the manifesto, Terry Scuoler, CEO of EEF, said: “This is a blueprint for the future of manufacturing and for policies that will support the demand not just for more skilled workers, but for more workers with higher-level skills.”

The CBI survey of 522 firms revealed that manufacturing output growth has reached its highest peak in seven months, during February. The food and drink sector was also among the fastest growing manufacturing sub-sectors in the three months leading to February.

59% of manufacturers in the food and drink sector reported a rise in manufacturing output, with just 22% reporting a loss.

Strong export levels were also recorded, with 25% of companies exporting over and above normal levels, with just 4% reporting a dip in exports.

A CBI spokesperson said: “Since food and drink is the UK’s largest single manufacturing sector, it was the greatest contributor to overall UK manufacturing growth over that period (three months leading to February).

“Although the sector plays a relatively smaller role in manufacturing exports than it does on the domestic scene, food and drink was nonetheless the second-largest contributor to export orders’ strength in February.”

FOOD AND DRINK PRODUCTION IS LEADING GROWTH IN THE UK’S

MANUFACTURING SECTOR, ACCORDING TO THE LATEST INDUSTRIAL TRENDS

SURVEY FROM THE CONFEDERATION OF BRITISH INDUSTRY (CBI).

In-depth

ISSUE 22 www.eriks.co.uk/knowhow6 7

In-depth

ENERGY-SAVING MADE MANDATORY

IF YOUR BUSINESS IS LARGER THAN AN SME, YOU HAVE UNTIL 5TH DECEMBER TO COMPLY WITH THE LATEST ENERGY LEGISLATION. OR YOU COULD FACE A FINE OF ANYTHING FROM £5,000 TO £50,000 POUNDS.

Does your organisation employ more than 250 people? Does it have an annual turnover of more than €50 million and an annual balance sheet of over €43 million? Is it an overseas company with a UK-registered establishment, employing 250 or more employees paying income tax in the UK? If it matches any of those descriptions, then it qualifies for the Government’s mandatory Energy Savings Opportunity Scheme (ESOS). And it’s time you started to take the necessary steps to comply.

Although non-compliance could land you with a fine of up to £50,000, acting on this initiative could bring you energy cost-savings which amount to as much or more in the long term. So it’s worth finding out what’s involved, and how to go about meeting the requirements before the December deadline.

Billions off the energy billThe Government expects ESOS to help UK companies to identify £1.6 billion of savings from their total energy bill, as well as helping to cut carbon emissions. It’s all part of the drive to reduce UK greenhouse gas emissions by 80% by 2050, as well as being part of the UK’s response to Article 8 of the EU’s Energy Efficiency Directive.

But it’s not just the country – and ultimately the Earth – which will benefit. By auditing and then using that work to reduce their energy use, businesses can expect to make significant savings for themselves.

The energy use that has to be audited is defined by ESOS as all energy products supplied to and consumed by an organisation, and includes combustible fuels, heat (but not surplus heat from industrial processes), renewable energy and electricity. So if the scheme helps you to identify where your organisation can save energy cost-effectively, you’ll see real benefits in increased profitability, greater competitiveness and improved sustainability but only if you act on the findings.

How to avoid the finesAs already explained, ESOS is mandatory for organisations which meet the size criteria. But, if your business is already certified to ISO 50001 – and if the certification relates to 100% of your energy usage – then you effectively already meet ESOS requirements. In that case, all you have to do is notify the Environment Agency that you are ESOS compliant.

If you don’t have the relevant ISO 50001 certification, you need to undertake an ESOS assessment. And although the deadline might seem a long way off, with the rush to comply as the date nears – and the inevitable backlog and delays that it will bring – then the sooner you take the necessary steps, the better.

SO, WHERE DO YOU START?

Assess, analyse, alterIf your organisation falls under the ESOS requirements, your first step is to calculate your total energy consumption. This means energy consumption for all activities, including properties, processes and transportation.

Once you’ve done that you need to appoint a lead assessor to audit your energy usage. The assessor can be an existing employee or an external contractor – as long as they are a member of an approved ESOS lead assessor register. As you would expect ERIKS offers a lead assessor service and is a member of an approved register. The lead assessor then has to audit your current energy usage by breaking it down into its different usages, analyse potential variations which may reduce energy efficiency, and suggest alterations and cost-effective measures which will save energy.

Finally, the lead assessor must compile an Evidence Pack for submission to the Environment Agency before the December deadline.

Making ESOS payObviously there’s a cost – in the form of a fine – if a company affected by ESOS doesn’t comply. There’s also a cost in carrying out the assessment – though for most companies, that will be a fraction of annual energy spend.

But the cost – and more – can potentially be recouped simply through the savings made through reducing energy use if you implement the findings. And since ESOS requires a repeat audit every four years, energy use will continue to be reduced, saving even more money as time goes by. And that’s only in terms of energy costs. As mentioned earlier, there are competitiveness and sustainability benefits to be realised too.

The extra mileOnce an organisation has complied with the requirements of ESOS, that’s all it has to do. But given that energy saved equals money saved, many businesses will take the opportunity to go further, to realise more savings.

An experienced and effective lead assessor will also go further, to help businesses comply with ESOS in good time to beat the deadline, and also to help them realise optimum savings.

As Europe’s leading industrial services partner, ERIKS has the benefit of experience of more industries, businesses and processes. We also have the advantage of being able to transfer knowledge from one to another, to apply proven solutions with a demonstrable savings track record to new areas, for cost-effective energy-saving results.

ESOS makes saving energy mandatory. ERIKS makes ESOS easier.

Technology update Technology update

8 9ISSUE 22 www.eriks.co.uk/knowhow

ERIKS launches hygienic duct joint for Food & Beverage applications

ERIKS targets compressed air inefficiencies through dedicated savings programme

End users are often faced with the dilemma of either having to use low cost worm clamps which may not meet the stringent hygiene regulations demanded by many of the UK’s industrial sectors, including food and beverage, and pharmaceutical; or expensive manufacturers’ crimped ducting assemblies which might be compliant, but come at a noticeable premium.

To help solve this issue, ERIKS’ new Steri-Clamp system provides end-users with an easy-to-fit, reusable jointing mechanism for ducting, which is Food and Drug Administration (FDA) compliant.

Free from phthalate plasticisers, Steri-Clamp features a unique ether polyurethane cuff which forms a vacuum and pressure tight seal to ensure maximum system continuity without the risk of contamination from external elements. What’s more, the joint will help maintain electrical conductivity and anti-static properties when used in hazardous environments.

The Steri-Clamp is available in sizes ranging from 1" to 4". Other ductings are available in PVC, silicone, neoprene and aluminium.

Some sites are losing as much as 60% of their compressed air pressure through leakages, with the industry average sitting at an unhealthy 30% loss of the total produced. Contrary to popular belief, air is ‘not free’ and the extra demand to cater for the losses has an expensive knock-on effect on a system’s energy consumption, and subsequently its cost.

In order to demystify the area, ERIKS has launched its Compressed Air Savings Programme, supported by both its FLEXION and A brand product offering

along with the impartiality of their Fluid Power Application Engineers. The process first examines the existing compressed air system, and identifies any areas which can be quickly rectified, such as basic repairs and replacements of non-active parts including gauges and fittings.

A comprehensive overall system audit is then used to pinpoint non-essential and inefficient areas of use which can be improved, in order to reduce compressed air usage down to the minimum required for effective operation.

By conducting this kind of audit ERIKS has been able to save customers millions of pounds on the production cost of compressed air, whilst also saving tonnes of unnecessary CO2.

Find out more at www.eriks.co.uk/flexion

The company – a burger, sandwich filling and snack foods manufacturer – had previously been making regular adjustments to the old chain, as a result of elongation caused by premature wear.

Another problem was lubricant from the chain dripping onto electrical switches below and causing damage. The switches were in a position which made them almost impossible to protect. Yet they cost £200 each and were having to be replaced every two to three months.

With frequent and lengthy production line shutdowns required either to adjust the chain or replace the switches, downtime costs were rising to unacceptable levels. However, since the original chain was replaced with Renold Syno chain seven months ago, there has been absolutely no maintenance required.

The Fenner PLUS range of adapted chains builds on the existing heritage and expertise within the power transmission market to deliver a new adapted chain with the optimum combination of tensile strength, wear resistance and fatigue life to cope in highly demanding industrial applications.

Available in both carbon and stainless steel variants, the new range of Fenner PLUS adapted chains meets the British (BS) standard specification. In order to offer a much more resilient offering and extended chain life, the new PLUS range also

includes solid rollers which are manufactured to achieve a much higher surface hardness than traditional chains, and also features shot peened plates for increased fatigue resistance. What’s more, all Fenner PLUS chain plates are progressively punched to give excellent accuracy of both diameter and pitch, and can operate successfully without regular lubrication.

For more information, please visit www.fptgroup.com/chain

ERIKS HAS EXPANDED ITS HOSE TECHNOLOGY OFFERING TO INCLUDE A BRAND NEW RANGE OF

REUSABLE FLEXIBLE DUCT CLAMPS, PROVIDING THE IDEAL SOLUTION TO HELP SAFELY HANDLE POWDERS

AND GASES IN HYGIENIC APPLICATIONS.

DESPITE BEING VIEWED BY MANY WITHIN THE MAINTENANCE AND ENGINEERING

PROFESSION AS A ‘LOW COST’ POWER SOLUTION, COMPRESSED AIR IS

A SURPRISINGLY EXPENSIVE RESOURCE WHICH COULD BE COSTING THE

INDUSTRY MILLIONS OF POUNDS THROUGH WASTAGE, LEAKAGE AND MISUSE.

A SNACK FOOD MANUFACTURER HAS DRASTICALLY REDUCED MAINTENANCE

ON ONE OF ITS MOST ARDUOUS APPLICATIONS, BY INSTALLING RENOLD SYNO

LOW-MAINTENANCE CHAIN.

NEW TO THE FENNER RANGE IS AN ADAPTED CHAIN OFFERING TO PROVIDE

END-USERS WITH A MORE ROBUST AND RELIABLE HIGH PERFORMANCE

POWER TRANSMISSION SYSTEM FOR USE IN HOSTILE ENVIRONMENTS.

Fenner adapts to market demand for high performance PT chain Fast food chain

Find out more at: www.eriks.co.uk/Stericlamp

Find out more at www.eriks.co.uk/Renold-Syno-Chain/4080

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ISSUE 22 www.eriks.co.uk/knowhow www.renold.com/attachmentchain

Contact ERIKS, your Renold authorised distributor on

0845 006 6000

Attachment Chain from Renold.

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EXCITING NEWS★ ★ ★ ON A DRY SUBJECT ★ ★ ★

IF YOU’RE INVOLVED IN FOOD PROCESSING OR PACKAGING, CHEMICALS OR PHARMACEUTICALS, WATER CONTAMINATION FROM COMPRESSED AIR IS A SERIOUS RISK. SO DRY IS PRECISELY WHAT YOU WANT TO BE. WHICH IS WHY THE LAUNCH BY IMI PRECISION ENGINEERING, WITH THE SUPPORT OF ERIKS, OF A NEW AND INNOVATIVE IMI NORGREN DRYER TECHNOLOGY IS EXCITING NEWS, AND VERY DRY TOO.

In line with ERIKS’ Planet+ initiative, IMI Precision Engineering’s new Hydra-D range of ultra-high purity desiccant air dryers delivers positive risk reduction and positive energy reduction. The Dryer, which is part of the IMI Norgren product family, can dramatically reduce the risk of water contamination from compressed air. It also significantly reduces energy use, through its energy saving design.

Swinging into actionCompressed air – like any air – contains moisture. When the air cools, the moisture condenses to water droplets, and it’s the water droplets that create the risk of equipment damage, process contamination, and even the growth of micro-organisms.None of those is a scenario you’d want in any industry. But for food, chemical or pharmaceutical industries, the presence of micro-organisms anywhere in the process or finished product would be catastrophic.However, unlike traditional dryers, the IMI Norgren Hydra-D range minimises the risk by using the pressure swing adsorption principle to dry the compressed air.

Doubly effectiveThe Hydra-D dryers – which can be wall or floor-mounted – feature a heatless twin tower configuration, housed in a strong, corrosion-resistant, modular design. Both columns contain a desiccant cartridge, and both cartridges incorporate inlet and outlet filtration.

The result of this dual filtration is increasedenergy saving, through improved flow distribution which results in enhanced performance with a lower pressure drop. So purge air for regeneration is as little as 15% and, in addition, purge only occurs when the bed is regenerating, thanks to dew point monitoring – which can save up to 60%.

Continuous supplyThe Hydra-D dryer is controlled by a robust and reliable programmable logic controller (PLC) system, featuring PLC memory retention. This system periodically switches the solenoid valves during operation, which reverses the function of each column to ensure a continuous supply of dry air. But this is not just any dry air. It’s dry air delivered in accordance with the highest industry standards, by dryers which are 100% leak-, function- and performance-tested. As Colin Billiet of IMI Precision Engineering explains: “The new dryers draw on proven desiccant drying technology, delivering clean, dry air for functions where air quality cannot be compromised. The Hydra-D range incorporates new patented features which deliver increased reliability, with reduced running costs and simplified maintenance.” Which, you’ll be pleased to hear, all sounds rather dry. For more information, visit www.imi-precision.com/dryers

Focus on food and beverages


FOOD AND BEVERAGE:

REDUCING THE EFFLUENT DISCHARGE CHARGEWater efficiency is becoming an increasingly high profile issue for the food and drink industry with both retailers and producers looking at ways of improving the way they use resources.

Sainsbury’s has now opened two ‘water neutral’ superstores, in Weymouth and Leicestershire, while Marks & Spencer says sustainable water management is moving to the top of the corporate agenda. On the processing front, a project at Coca-Cola’s bottling plant in Wakefield has achieved a tenfold reduction in wastewater generation – down to an average 60m³/day.

UK producers of food and beverages currently use 360 million cubic metres (m3) of water a year – more than half of the total used by industry. Distilling, meat manufacture and food and vegetable production are among the heaviest users of water in UK industry.

Government campaigns have already tried to show how water can be used more efficiently, with some success. As well as cutting down their water usage, companies wishing to improve their environmental credentials should also be looking carefully at how to reduce the amount of chemicals, oils and pollutants being released into the public sewerage system.

Reduce consumptionResearch carried out by the non-governmental waste advisory body WRAP suggests many water-intensive companies can reduce their sewage and effluent bills by a third by focusing on efficiency measures – some of which can be implemented for very little cost.

A voluntary initiative to reduce water use in the food and drink industry ran from 2007 to 2011. The 70 British companies who signed up to the Federation House Commitment reported a 15.6% reduction in water use – over 6,000m³. Any reduction in the volume of water used through reduction of leaks, increased efficiency and water recycling will result in a lower effluent treatment bill.

Initially, reducing volume can be quite straightforward. WRAP recommends creating an inventory of water use – working out exactly how much water each part of the process uses and looking at ways to reduce waste.

TechnologyThere is a whole world of emerging technologies which can decrease both water and sewage use. In some cases effluent waste can be treated on site – generating by-products such as animal feed, or even generating renewable energy.

In Dorset, BV Dairy has not only cut effluent costs, but also cut its energy bills by 30% by opening an anaerobic digestion plant that converts its fatty waste products into fuel. It is a great example of the way tackling waste management can save money and improve the carbon footprint of the industry.

Mogden FormulaIn the UK, the charge for trade waste is calculated using the Mogden Formula, which works on how much wastewater is removed and how much treatment it needs.

The charge was initially intended to cover the cost of the removal and treatment of wastewater – however many areas now include additional charges for taking out pollutants such as phosphates. The Mogden Formula is calculated on the basis of the volume of wastewater discharged directly into the water company’s sewage system with additional charges for the chemical oxygen demand (COD) and suspended solids (SS) levels in the effluent.

The COD measurement relates to the amount of organic compounds in water, while SS refers to non-soluble particles of matter. In order to reduce sewage charges, a company should consider ways to reduce the overall volume, COD and SS being released.

Contaminant removalOne of the simplest forms of treatment for low volume sites is to have an interceptor to remove contaminants such as oil, grease and silt from water run-off before it is discharged into the watercourse. Appropriately designed and maintained interceptors are particularly good at taking out SS. It is usual for sites to install a pH monitor to ensure the discharged effluent is compliant.

MicropollutantsAs well as reducing water and sewage costs, it is also important to consider treating wastewater for micropollutants – which are increasingly regulated by the European Water Framework Directive. Businesses need to be aware of the contaminants they may be producing as part of the industrial process and, if possible, introduce an onsite treatment plan that removes these before they are released into the environment.

InnovationGlobally there is a huge amount of investment in technology, which can help make businesses more water and energy efficient. A recent report from Blue Tech Research suggested the potential global market for water-efficient technologies alone was worth £1.9bn each year. This gives companies an unprecedented

opportunity to identify the treatment technologies and systems that will deliver the best-cost outcomes to their business.

Multinational food company Nestlé has demonstrated the kind of water efficiencies that can be achieved in a recent £11 million upgrade of a dairy plant in Mexico. The plant’s zero liquid discharge reuse system uses water extracted from powdered milk production to supply all its onsite water requirements.

The way forward – a greener futureAlthough the Federation House Commitment has now expired there are still incentives for food and drink manufacturers aiming for more efficient water use, less waste and fewer pollutants released into the environment. The Enhanced Capital Allowance scheme offers a 100% first-year allowance for investments in water efficient plant and machinery – letting businesses write off the cost against taxable profits in the year of purchase.

Globally the need to make business water neutral is becoming a high priority – with companies such as Pepsi among the first to be recognised as ‘water positive’ in their processing operations. In the UK water neutral supermarkets and low impact dairy farming are making inroads towards sustainability, but much more needs to be done.

Figures calculated by Tesco suggest the water embedded in the products on its shelves are thirty times that of the water needed to run the stores, offices and distribution centres. Given their enviable market position and need for reputational advantage, large food retailers could work much more closely with their suppliers to support investment in water efficient processing.

Global warming and increasing population mean water worldwide is set to become an increasingly expensive, scarce and precious resource. In the UK we tend to take both the water supply and the sewage system for granted – but we need to change our way of thinking.

With the help of good management, technological innovation and creative thinking the food and drink industry has the potential to lead the way.

Natasha WisemanManaging Director,WiseOnWater

Natasha Wiseman is Managing Director of WiseOnWater, a media consultancy specialising in the global water and wastewater industry. With over ten years’ experience, Natasha is the former editor of World Water and Water & Wastewater Treatment magazine, the UK’s leading water industry publication.

Focus on food and beverages Focus on food and beverages

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Food and beverage production is increasingly tightly regulated and monitored. There’s a growing mountain of product compliance requirements (from NSF to FDA), and certifications such as HACCP. But it doesn’t end there.

As in all industries, food and beverage producers are under increasing pressure to set and achieve targets for environmental performance and sustainability – all of which can be positively or negatively affected by the way maintenance is carried out.

Last but not least, the production environment of the food and beverage industry is often a highly demanding one, with extremes of temperature to be dealt with, moisture to be eliminated, process contaminants to be avoided, and the need for frequent and aggressive hygienic cleaning.

All of these factors can contribute to equipment degradation, are key considerations in lubrication requirements, and can have a powerful impact on lubricant performance.

Problem or solution?Lubrication and re-lubrication are essential elements of any plant maintenance regime. But some lubrication practices and actions can actually cause as many problems as they solve. For example:

n Frequent relubrication has cost implications, both for the purchasing of grease and the labour involved in the relubrication process

n Relubrication involves purging of bearing positions

n Over-lubricating can pose a food safety risk through contamination

n Relubricating in hazardous working areas with difficult access means an increased risk to the safety of maintenance technicians

n Leaking lubricants due to failed seals can create a slip hazard for maintenance staff and operators

n Correct relubrication demands certain levels of knowledge and skill. Achieving and retaining the necessary resources within the industry is a growing challenge

n Industry figures suggest that around 36% of rotating equipment failure occurs due to inappropriate lubrication

The cycle of wasteOne of the common practices familiar to everyone in the food and beverage industry is the hygienic washdown followed by relubrication.

During this process, excess grease in bearings is often discharged past the bearing seals. Known as purging, this can compromise not only food safety, but also the safety of personnel, and the reliability and service life of the asset involved.

Ultimately, during the next washdown cycle, the excess grease is washed away and into the facility’s waste water. (See left page).

This never-ending cycle of waste is a major cost in terms of lubricant and other resources, in addition to increasing the amount of lubricant discharged into the waste stream, at a risk to the environment.

In addition to the cost of the lubricant, there are also the labour resources and associated costs to be taken into consideration – all adding to an expensive process. A process which – with the help of SKF – could be rendered largely unnecessary.

Better lubrication managementAs already described, relubrication is not usually an option. But there are ways to carry it out which can mitigate against risks to food, operator safety, as well as eliminating the risk of excess lubricants entering the waste water stream.

By taking positive steps towards more effective lubrication management, and by adopting relubrication free technologies, asset performance and reliability can be maintained, while at the same time lubrication and its associated costs and challenges can be reduced or eliminated.

Among the dedicated technologies that help to manage the lubrication of food and beverage processing machinery, relubrication free bearings and advanced sealing systems are effective solutions.

SKF Food Line Y-bearing units, for example, are a relubrication free solution that enables increased productivity coupled with reduced costs.

Lubricant in, washdown solutions outSKF Food Line Y-bearing units feature a relubrication free, stainless steel bearing insert. Fitted with a very efficient multiple-lip seal and a rotating flinger on both sides, the units keep the lubricant in, and harsh washdown solutions out.

The bearing is fitted into a high-strength, composite housing that’s 60% lighter than cast iron, and resistant to hot and cold water, disinfectants, washdown chemicals, citric acids and cooking fats. The bearing units are HACCP compliant and pre-lubricated with NSF H1 grease, which is approved for use in all food processing operations.

The SKF Food Line Y-bearing can also be supplied with an effective end cover to comply with Health and Safety regulations.

Even under high-pressure washing, the bearing resists washdown solution ingress, and the lubricant remains in place.

So now you know you can continue to maintain your plant at peak performance through maintenance, and reduce your lubrication costs and waste at the same time, it’s a matter of not when, but now.

LUBRICATION: NOT WHEN, BUT HOW.

AS EVERY MAINTENANCE ENGINEER KNOWS, LUBRICATION – AND RELUBRICATION – IS NOT AN OPTION BUT A FUNDAMENTAL NECESSITY FOR MAINTAINING PLANT PERFORMANCE AND RELIABILITY. AND AS EVERY FOOD AND BEVERAGE PRODUCER KNOWS, FOOD SAFETY IS NOT AN OPTION EITHER. SO MAINTAINING PLANT WHILE MAINTAINING THE HIGHEST HYGIENE STANDARDS IS JUST ONE OF THE DAILY CHALLENGES THEY FACE.

WASHDOWN CYCLE

The traditional cycle of washdown and relubrication presents risks

to both bearing service life and the environment

SKF Food Line Y-bearing units support Foreign Body Prevention Programmes (AIB Gold Standard,

GMP, HACCP)

n Washdowns

n Detergent creep

n Water ingress

n Corrosion

n Waste water contamination

n Increased risk of foreign body ingress

n Relubricate to purge

n Frequent bearing replacements

To see a demonstration of washdown resistance, scan this code or go to the SKF channel on YouTube.


17

Used as part of a product’s make-up, for rinsing food – such as salads – and simply for washing-down equipment, water is an intrinsic part of food and beverage production. So ensuring it’s uncontaminated by the deadly cryptosporidium parasite is essential.

But how can you stop it entering your plant, mixing with your product, and ultimately reaching your end consumer – with potentially fatal results?

Removing the risksUsing the right filter for your water supply can minimise the risk of the cryptosporidium parasite and its associated risks.

Amazon Filters offer a choice of two filter cartridges – the SupaSpun II depth filter and SupaPleat II pleated filter – which have been proven in use with numerous food and beverage producers.

By installing these products to filter incoming mains water, you can demonstrate ‘due diligence’ in preventing contamination.

And you can ensure complete peace of mind for your customers and yourself.

Absolute protectionManufactured to cryptosporidium grade (CRY), with (Absolute) removal ratings ranging from 0.3 to 180µm (Beta Ratio 5000), Amazon Filters provide consistent and reliable cryptosporidium removal performance, with a typical 104 log reduction value.

Manufactured from 100% polypropylene to meet FDA requirements – the filters are manufactured using a thermal bonding process. This eliminates adhesives, minimises media migration and creates minimal extractables which could contaminate products.

For more challenging applications, the XP extended life version is also available.

Specialist support Contamination by cryptosporidium is a constant danger where water is present.

So it’s vital that you choose the correct filter for your application. And once it’s installed, it’s also vital that you keep it maintained and operating at its optimum.

ERIKS together with Amazon can help you with such issues, using the skills and expertise of filtration application engineers to help you reduce the risk of water contamination – from Crytosporidium and other causes.

FROM CAUSING FATALITIES TO KILLING A BRAND’S REPUTATION, THE CRYPTOSPORIDIUM PARASITE – FOUND IN WATER – IS A VERY REAL DANGER IN ANY FOOD OR BEVERAGE PRODUCTION PROCESS. FORTUNATELY THERE IS A SIMPLE, RELIABLE AND COST-EFFECTIVE FILTRATION SOLUTION.

CRYPTOSPORIDIUM – THE FACTS

n Potentially fatal parasite found worldwide in water systems

n Causes 50.8% of water-borne diseases that are attributed to parasites

n Causes symptoms including severe diarrhoea – lasting up to two weeks even in healthy adults

n Causes more serious problems in the young, elderly and immunocompromised

n Protected by an outer shell that allows it to survive outside the body for long periods of time

n Very tolerant of chlorine disinfection

QR CODE TO BE

CHECKED/UPDATED

... And we haven’t even talked about the lubricant yet ...

With packaging thisadvanced imagine howthe product performs

DETEX® metal & x-ray detectable cap and actuator

360° minijet directional spray valve

Date of manufacture

Multi language -14 languages

NSF Category & Registration number

ISO21469 Certification

Unique lubrication management reference number

Application icon

Contact ERIKS, your ROCOLauthorised distributor for details on 0845 006 6000 or visit www.rocol.com

DETEX metal & x-ray detectable plastic components are recognised by

the Food Processing Industry as an award winning innovation.



HIGH-WIRE ACT

BALANCING THE PERFORMANCE CHARACTERISTICS REQUIRED OF CABLES, AGAINST THE TOUGH HYGIENE REQUIREMENTS AND OPERATING ENVIRONMENTS OF THE FOOD, BEVERAGE AND PACKAGING INDUSTRIES, IS LIKE WALKING A TIGHTROPE FOR CABLE MANUFACTURERS.

With a potent mix of chemicals, a wide range of temperature variations, and a variety of physical stresses to contend with, cable solutions for the food, beverage and packaging industries need to satisfy a huge variety of demanding criteria. In refrigeration areas or moist atmospheres, and from aggressive acids to equally aggressive alkalines, they need to be able to stand up to the worst without fatigue, degradation or failure.

Equally, food and beverage producers need to know that not only will their environment not harm the cables, but also that the cables won’t harm the products they come into contact with.

It’s a difficult balance to achieve. But as one of the world’s leading providers of cables, and with 40,000 standard items available from stock, Lapp Group has the cable solutions for control, connection and conduits.

Robust by name…The ÖLFLEX® ROBUST range of flexible control and connection cables is UV resistant, tough, and robust even when exposed to

aggressive substances such as vegetable-based oils, fresh, processed or sewage water, cold, warm or even – for short periods – hot beverages, or a number of chemicals.

The outer sheath lasts far longer than a standard rubber version: under exposure to heated steam, more than ten times longer, in fact. And the cables themselves are harmless to foodstuffs – being free from evaporating substances and from heavy metals or other RoHS blacklisted substances.

Available for connection or control – with or without a copper braided screen – the ÖLFLEX® ROBUST range also includes a highly-flexible version for constantly moving applications.

A classic solutionThe polyurethane-sheathed cables in the ÖLFLEX® CLASSIC range combine tear-resistance and flexibility with high tensile strength, very high resistance to mechanical and chemical damage, and high-resistance to tangling and knotting.

ÖLFLEX® CLASSIC 400PFor high resistance to chemicals, oils, greases and other aggressive substances. ÖLFLEX CLASSIC 400CP contains a tinned copper wire braid for environments where EMC is a consideration. Both versions are suitable for use in a temperature range of –5°C to +70°C.

ÖLFLEX® CLASSIC 450PFeaturing a PVC inner sheath for increased durability. The yellow polyurethane outer sheath is flame-retardant and resistant to chemical agents, diluted acids and aqueous alkaline solutions.

ÖLFLEX® CLASSIC 440POffering the same mechanical and chemical resistance as the 400P, but with TPE core insulation – enabling use in a temperature range from –40°C to +90°C. Also available with a tinned copper wire braid to meet EMC regulations.

Making the connectionThe world-renowned SKINTOP® Cable Gland is now approved to IP69K rating, in accordance with DIN 40 050. So now

it can connect even in applications with the harshest cleaning procedures, involving high-pressure cleaners and hot water.

The SKINTOP® ST-M range of glands is made from glass-reinforced nylon, in a choice of colours, and thread sizes from 12–63mm. It can accommodate cable with an outer diameter from 1–45mm. The SKINTOP® MS-M range is made from nickel-plated brass, for use in areas with a high mechanical demand and a need for chemical resistance. Available in thread sizes from 12–75mm, the range can accommodate cable with an outer diameter from 1–68mm.

High-tech solutionWhere automation is at an advanced level, it places a high level of stress on conventional cables, leading to fatigue and failure. However, the ÖLFLEX® FD range of robotic cables has been specially designed for high-technology applications, and as one of the most flexible available is able to withstand rigorous and heavy duty operations.

The cable make-up includes very fine wire conductor stranding, with a high rate of twist on the strands and conductors. The increased rate of twisting reduces stress at the point of bending. Other features include extra chalk, textile separator tapes, and a specially-formulated polyurethane sheath for hydrolysis and microbe resistance. Very small bend radii and copper braid versions are also available.

Lapp also manufacture two conduits: in coiled corrugated plastic and in halogen-free stainless steel.

The SILVYN® FD-PU plastic conduit is highly flexible and offers protection against oil, grease and benzene at high temperatures. The SILVYN® SSUE stainless steel conduit is ideal for measurement, instrumentation and safety applications in the food and beverage industry.

Making your markWhen you’ve chosen your Lapp cable, you can leave your mark on it with the Lapp FLEXIMARK® kit. Featuring stainless steel character holders,

character strips and cable ties, the kit makes it easy to mark cables, components, pipes and devices in demanding and aggressive environments.

If you’ve marked any of these Lapp products as being suitable for your cabling requirements, visit www.lapplimited.com.

WHEN THE GOING GETS TOUGHThe most common cases of cable failure in the food and beverage industries are microbe infestation and hydrolysis.

Microbes and bacteria can degrade cables made with organic substances – and even high levels of cleanliness won’t prevent the natural degradation process. Cable sheaths can also become a nutrient medium for microbes and bacteria, providing a breeding ground as well as degrading the insulation material.

With water and steam jets used for high-pressure cleaning in the food and beverage industry, hydrolysis – or flushing of substances from the sheaths – is a frequent occurrence. This allows degradation to begin, and the insulating material also becomes brittle.



IF ANY SINGLE BUSINESS CAN CLAIM TO BE KEEPING THE FOOD AND BEVERAGE INDUSTRY MOVING, IT WOULD BE REXNORD FLATTOP EUROPE. AROUND 80% OF TURNOVER FOR THIS EUROPEAN DIVISION OF REXNORD COMES FROM STANDARD AND CUSTOMISED CONVEYOR CHAINS AND ACCESSORIES TO MOVE ALONG PRODUCTS AND PROCESSES FOR THE BEVERAGE FILLING AND PACKAGING INDUSTRIES.

Parent company Rexnord is a leading worldwide industrial manufacturer of conveyor chains and components, headquartered in the USA but with employees and distributors in more than 100 countries. As well as the food and beverage industry, globally the company serves sectors as diverse as mining, water management, aerospace, construction, energy, hydropower, manufacturing and petrochemical. And it’s continually developing and introducing new chain and component products.

Drink or dry?One of the latest developments is ideal for beverage lines, or lines – such as packaging – where cardboard dust may be present. This new generation of roller transfer plates will operate on fairly dirty lines without the risk of causing a roller blockage.

As Mr. Daniele Coen, Rexnord FlatTop Component Marketing Director, points out, Rexnord is also, “very active in terms of materials, in particular for dry running materials that have no lubricant added. These materials are beneficial in both economical and environmental terms.” Removing the need for lubrication also removes any risk of contamination on food and beverage production lines.

The high-performance, energy-saving Combi X Corner Track Magnetflex® System operates without lubricant – even at high speed. Currently available for use with magnetic chains, future developments will enable it to be employed with other chain types.

The Combi-X Curve is manufactured at the company’s Italian production site in Correggio, Reggio Emilia, in the north-eastern area of the country. This site – which has its own R&D facility – produces standard and customised products including plastic

chains and static and dynamic components. The increase in production of the Combi-X Curve in particular has led to major investment and a huge expansion at the site.

Flexibility and no frictionAnother new FlatTop product is the Ultra Low Friction (ULF) Next Generation Guide Material, which offers low-friction, even at high speeds. In addition, it features the patented Side Guide Adjustment™ (SGA), which offers a fine side guide regulation with 16 different positions and 2mm gaps. This means it’s highly flexible and can be used for several different types of products. The range also includes new lateral roller guides, which deliver high efficiency together with low conveyed-product damage.

Made in The Netherlands, Italy and China, and…Though Rexnord FlatTop has headquarters in the USA, Rexnord FlatTop Europe is head-quartered in The Netherlands, and employs around 350 people, mainly in The Netherlands and Italy.

Production sites in the USA, The Netherlands, Italy, China and Brazil produce a range of products, including bearings, couplings, gears, industrial chain, conveying equipment, FlatTop chains and components. The division also develops and manufactures products for managing and enhancing water quality, safety, flow control and conservation.

A relatively new sector for the European division, currently representing about 20% of turnover, is the industrial automotive industry. The Rexnord FlatTop 3125 and 6990 product lines were both developed specifically to meet the needs of this sector, being designed to enhance conveyance in the industry.

In addition to the Combi X Curve, the Italian production facility produces standard and customised products, including plastic chains and static and dynamic components. The Dutch facility, located in ‘s-Gravenzande, manufactures plastic and steel chains.

Patented for packagingFor the packaging industry, Rexnord FlatTop has developed the patented ZeroGap™

product, and the PSX material which is suitable to run dry in many applications. Specific chains have also been developed for in-line accumulation and cardboard bricks conveyors. These chains are ideal for use on compact conveyors, providing maximum continuity of conveying surface, smooth transportability and enhanced safety.

The specialised Rexnord FlatTop products are mainly produced in Europe and America, for shipping all over the world. Both customised and standard products are available, and the degree of product specialisation covers a wide range.

Satisfying customersUnderstanding and meeting the needs of customers in the food and beverage and other industries is of paramount importance to Rexnord. To help them achieve this, they employ an internal system called the Rexnord Business System (RBS).

Daniele Coen explains that this is, “a process-based framework built on the idea of continuous improvement, which covers quality, working methods, and the management of relationships with other companies within Six Sigma and lean manufacturing frameworks. Using RBS allows us to continuously create value for our customers.”

Highly-automated production processes allow Rexnord to efficiently and cost-effectively serve the global market, with products marketed under three brands: Rex® and MCC® for chains, and Marbett® for components.

Looking to the future Mr. Coen says that, “Rexnord FlatTop will continue to grow in an organic way in the beverage market, while actively pursuing new customers in the food market and automotive industry. The component side of the business always gives us the opportunity of acquiring new clients in the beverage market whilst – given the wide range of products that we have to offer – actively pursuing new customers in the food market and the automotive industry. It also gives us the opportunity to further develop customised products for these same clients or for their sectors.”

To discover more about the vital links Rexnord FlatTop can provide for your processes, visit: www.rexnordflattop.com

Daniele CoenRexnord FlatTop Component Marketing Director


22 ISSUE 22 www.eriks.co.uk/knowhow

That’s something we expect to hear more and more in connection with the Grundfos Hilge F&B HYGIA family of pumps. These pumps were developed especially to meet the most exacting hygiene and precision demands of the brewing, dairy, soft drinks, food and pharmaceutical industries, the range has proven itself worldwide as a real hygienic pump alternative.

Efficiency savingsA brand new Grundfos Hilge F&B HYGIA can save you money in more ways than one.

First, it typically costs around the same as a refurbished obsolete hygienic pump, such as an APV Puma. Second, because it’s powered by an IE3 energy efficient motor, its running costs will be significantly reduced compared to traditional motor types.

And because only minimal pipework modifications are usually required to replace an existing pump with a Grundfos Hilge F&B HYGIA, upfront costs are also reduced.

A new Grundfos Hilge F&B HYGIA that is manufactured from cold drawn 316L stainless steel and with a polished surface finish the range is fully hygienic, EHEDG compliant and designed for cleaning in place (CIP) and will deliver:

n Significant financial and environmental energy efficiency benefits

n True field-proven reliability

n Readily accessible/responsive service

n Genuine spare parts

n A free 5-year warranty

When you weigh up all these many plus points that will be attained by installing a new F&B HYGIA pump and additionally consider that such a replacement will also overcome the many challenges faced with managing the constant ‘at risk’ status, the rationale and decision process required to make the leap and decide to change becomes much easier.

This is something that a large blue chip food manufacturer is currently discovering for themselves. Set across multiple sites in the UK, their production demands an army of hygienic pumps to complete their processing.

However with lines brought in from different sites and many that have been in situ for years, they needed to establish the current demands. This is where an F&B HYGIA complete with e-motor is being used as a control, to check the current flow rates and pressures. This test rig has already

highlighted significant opportunities for energy saving and improved efficiencies.

The company have been both surprised and pleased by the results to date and are now planning to complete this exercise on all their current Puma plant with a view to replacing them with F&B HYGIA products. This is a clear demonstration that these F&B HYGIA pumps can deliver both peace of mind and cost efficiencies – so to get the best from your hygienic systems – demand Grundfos, because a change is much, much better than a quest.

IF IT AIN’T BROKE – WHY FIX IT?RELUCTANCE TO CHANGE IS AN UNDERSTANDABLE HUMAN TRAIT. BUT IT’S ALSO OFTEN RESPONSIBLE FOR HOLDING BUSINESSES BACK – AND THE FOOD INDUSTRY IS NO EXCEPTION. YET THE OTHER PHRASE WE OFTEN HEAR AFTER A REVIEW AND RENEWAL OF HYGIENIC PUMPS IS: “WHY ON EARTH DIDN’T WE DO IT SOONER?”

ARE YOURUNNINGAT RISK?

Today's food and beverage production facilitiesdepend on maximum uptime. Howeverour experience shows that many pumpinstallations are overlooked until failure occursand it is discovered that vital models havebeen discontinued and spares and support areno longer available.

Grundfos has a full range of modern, reliableand energy efficient sanitary pumps, allbacked by legendary service and support. Withcosts far closer to refurbished discontinuedequipment than you might think, no longer isthere a need to run plants at risk of failure.

To nd out how to get a free ve year warranty and service pack with the latest F&B HYGIA hygienic pump from Grundfos, talk to the ERIKS sales team today.

Created w

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.lindblad.biz



EfficienciesMaximising ProductionFood & Beverage Processing

By selecting and maintaining critical components inside rotating plant and machines, food and beverageprocessing companies eliminate production downtime and increase the operating life and reliability ofplant equipment says Dr Steve Lacey, Schaeffler Technology Centre Manager at Schaeffler UK.

In food and beverageprocessing, productionis typically based onhighly automated, fastmoving processes andsystems, where everysecond of productioncounts. In theseoperating environments,the cost of productiondowntime can equate tohundreds of thousands

of pounds per day. Total maintenance costs for a typical food or beverage manufacturer arearound 15-20% of total costs. Quiet running,energy efficient and reliable mechanicalcomponents such as bearings that offer longeroperating life times, play an important role in

the Total Cost of Ownership of critical plantand machinery.

Bearings for every applicationFor food, beverage and packaging machineapplications, Schaeffler offers a wide range of robust, reliable bearings, which can all becorrosion protected, sealed and lubricated for life for continuous operation.

The Schaeffler bearing range includes deep groove ball bearings, radial insertball bearings, plain bearings, housed units, trackrollers, slewing rings and linear guidancesystems. All products are designed to fulfillseveral key principles, including compactdesign, maintenance-free operation, modularcomponents and reliable, long operating life.

Housed bearing unitsHoused bearing units are found in many food and beverage processing lines, frommaterials handling systems to conveyor beltdrives, pumps and fans.

Schaeffler’s range of housed bearings now includes units manufactured to JapaneseIndustrial Standards (JIS). In terms of theirhousing dimensions, borehole mounting andlubrication, the housing units are directreplacements for Japanese-manufactured units.The FAG Black Series of radial insert ballbearings and housing units are robust, costeffective, ready-to-fit machine elements thatprovide simplified mounting, smooth runningand high reliability.

Long maintenance intervalsAn innovative seal design and special coatingmake this range very economical for users.The housing is made from flake graphite castiron and is coated with 2-pack paint thatinhibits the formation of rust. A special one-piece seal with moulded lip and adjacentflinger shield protects against the ingress ofcontamination. Relubrication is easy as the sealis firmly staked in the outer ring, and there is norisk of the seal being pushed out of the bearingby excessive amounts of grease. Contrary tomany other radial insert ball bearings, this lipseal does not contain any harmful DBPplasticisers.

Multi-point lubricatorsFor food or beverage processing lines wheremachine uptime is critical, multi-pointlubrication systems can be installed, whichautomatically supply lubricant to rolling bearingswithout the need for manual intervention.

FAG CONCEPT8, for example, is a cost effective multi-point lubricator fromSchaeffler that ensures a constant, optimumsupply of grease to rolling bearings. The system is suitable for a wide range ofindustrial applications, including pumps, fans,compressors, gearboxes and electric motors.

FAG CONCEPT8 provides up to eight separatelubrication points for dispensing preciselymetered quantities of lubricant to rollingbearings. Unlike other multi-point lubricators,

FAG CONCEPT8 enables users toindividually control each pump in order tooptimise cycle times and volumes ofdispensed lubricant. Rather than having topurchase multiple single point lubricatorsto cope with different bearing lubricationrequirements, users can now buy

one FAG CONCEPT8.

HRS seals

Dr Steve LaceySchaeffler TechnologyCentre Manager

Black Series radial insert ball bearings with a spherical outer ring are based on deep groove ball bearings and aremanufactured to JIS B 1558. The outer rings,inner rings and shields are coated withDurotect® B – a thin matt black, mixed ironoxide layer developed by Schaeffler thatprovides high corrosion resistance.

The units are available as plummer blockhoused units, flanged housed units or take-uphoused units. Schaeffler also offers housedbearing units with corrosion-resistant(stainless) sheet steel or plastic (glass fibrereinforced PBT) housings.

Grease selectionSelecting the correct lubricant is a criticalfactor in ensuring the reliability and optimumoperating life of a rolling bearing. Failurestatistics show that a significant proportion ofpremature rolling bearing failures are directly or indirectly related to the lubricant used.

For food and beverage processing companies,legal and environmental factors must beconsidered when selecting a suitable grease.A worldwide standard that can be used isapproved in accordance with the NSF(National Sanitary Foundation) H1 or H2.

A lubricant with the code H1 (food-gradelubricant) may be used where occasional,technically unavoidable contact with foodstuffscannot be eliminated.

This means that the grease must be non-toxic,rapidly broken down by the organism andneutral in terms of both odour and taste. H2 lubricants are intended for general usewithin the food processing industry where nocontact with foodstuffs occurs.

Schaeffler’s ARCANOL range of lubricantsincludes 17 different greases, each onedeveloped by Schaeffler application engineers.These greases therefore provide specificlubrication properties for almost every type of industrial application, including food,beverage and packaging applications.

FAG CONCEPT8

FAG Black Series JIS standard radialinsert ball bearings

FAG Black Series Plummer block housing unit

KUVE linear guidance system

Deep GrooveBall Bearings

FAG Black Series - flanged housing unit

SCH 4721 Eriks Food and Beverage DPS (Final Artwork - Update3)_Layout 1 30/03/2015 16:23 Page 1

Time savings

26 ISSUE 22 www.eriks.co.uk/knowhow

The problems at this particular production facility were arising in their Scraped Surface Heat Exchangers. These were operating as part of a continuous process, and fouling of the heat exchangers – with a subsequent reduction in heat transfer efficiency – can occur. In fact, the internal scrapers are designed not only to mix the product but also to remove material build-up at the same time.

However, the customer had five heat exchanger units, and was experiencing twelve bearing failures a year – each one resulting in five hours of lost production and associated repair costs.

It was the loss of production which finally convinced the Production Manager he needed help. He called upon ERIKS’ unbiased technical know-how to help resolve the issue; ERIKS recommended that one of their partner suppliers, NSK, would be best able assist on this occasion.

Lubricant breakdownUnder the NSK Added Value Programme – AIP, NSK’s experienced application engineers help production and maintenance managers to understand the causes behind bearing failure. Then they suggest steps to put it right, to improve reliability and efficiency, and to reduce the frequency of breakdowns attributed to bearing failure.

By implementing this comprehensive programme, customers can expect to save time and money, and improve profitability and competiveness.

In this case, the NSK engineers conducted a failed-bearing analysis, which determined that both water and hard particles were contaminating the bearing, leading to a breakdown of the lubricant. To solve the problem, NSK proposed a trial of its Molded-oil deep groove ball bearings.

Maintenance-freeMolded-Oil technology has been developed by NSK to improve bearing reliability. The Molded-Oil system uses an oil-impregnated resin to provide lubrication to the bearing, which allows for maintenance-free operation. Similar designs are available from other bearing manufacturers, but offer a considerably lower lubricating oil content than the 50%+ by volume provided by the NSK technology.NSK offers its Molded-Oil technology on standard deep groove ball bearings, spherical roller bearings and tapered

roller bearings with inside diameters up to 110mm. The bearings can be manufactured from stainless steel for applications in corrosive environments, or for exposure in wash-down facilities.

60 hours and 96,000 savedThe trial period for the fish products manufacturer eventually ran to more than three years, but the bearing still showed no signs of requiring replacement. In fact, its performance was more than enough evidence for the Production Manager to request installation of the NSK solution across all five heat exchangers.

As a result, the company avoided repeated production shutdown and repeated maintenance and repair costs, saved 60 hours of lost production, and made cost savings of over €96,000.

The savings that didn’t get away60 HOURS OF PRODUCTION WERE BEING LOST EACH YEAR THROUGH REPEATED BEARING FAILURES, BEFORE A MANUFACTURER OF FISH PRODUCTS ASKED ERIKS FOR HELP.

PartnershiP based on trust – and trust based on quality

NSK UK Ltd · Northern Road, Newark, Nottinghamshire, NG24 2JF

Bearings for the food and beverage industry: compliant with the strictest hygiene requirements

NSK bearings for the food industry are robust, made from corrosion-resistant stainless steel, and have extended relubrication

intervals. NSK’s special solid lubricant, Molded-Oil, is suitable for use in areas where hygiene is paramount. Molded-Oil guarantees

reliable lubrication without oil leaks, safeguarding uninterrupted production and a long service life.

Contact ERIKS, your NSK authorised distributor, on 0845 006 6000 or visit www.nskeurope.com

NSK_F+B_A4.indd 1 25/09/2014 16:03:04

Best practice Best practice


CONDITION MONITORING: What, why and how

IF THERE’S ONE THING WORSE THAN A PLANT FAILURE, IT’S AN UNEXPECTED PLANT FAILURE – BRINGING PRODUCTION TO A GRINDING HALT AND TAKING TOO LONG TO RESOLVE. CONDITION MONITORING IS THE ART OF IDENTIFYING LIKELY PROBLEMS, AND EITHER PREVENTING OR BEING PREPARED FOR THEM. WHICH MEANS A PROBLEM DOESN’T GET THE CHANCE TO BE A CATASTROPHE.

Having been a recognised technique and discipline for several decades now, Condition Monitoring (CM) – and the associated Condition Based Maintenance – has its own ISO set of standards and its own defined process. This means that customers looking for CM services can be sure of finding a reputable provider, and can also follow a process which delivers the required results and continuing improvements.

Certified competenceIn the words of the ISO, standard 18436 part 2:2003, ‘specifies the general requirements for vibration analysis personnel who perform machinery condition monitoring and diagnostics of machines. Certification to this standard will provide recognition of the qualifications and competence of individuals to perform machinery vibration measurements and analysis using portable and permanently installed sensors and equipment’. Similar statements precede the other parts of this standard that cover certification in the rest of the condition monitoring technologies.

This standard means customers cannot only be sure they have hired a competent technician, but can also be confident that the solutions they recommend are right for the job. Over- or under-selling should be eliminated, because the Standard is administered by the British Institute of Non-destructive Testing (BINDT), whose code of ethics is incorporated in the standard.

ERIKS’ Condition Monitoring service, for example, employs only technicians who adhere to the BINDT Code of Practice for CM, and who are either Level 2 competence or working towards that certification.

Monitoring methodsThere are a number of methods for conducting effective CM, depending on the machinery being monitored. Thermography – monitoring for unusual temperatures which may suggest bearing wear or lubrication failure, for example.

Acoustic emissions – monitoring for unusual noise or noise levels which may suggest failing or failed components either by airborne or contact means.

Vibration monitoring – monitoring for unusual vibrations or vibration frequencies, which may suggest failing or failed components.

Lubrication analysis – regular monitoring of a lubricant’s properties, looking for change in viscosity, contaminants or particles of wear.

Electrical analysis – the supply current or insulation electrolytic strength can be monitored for changes or patterns that give an indication of condition change.

However, to be a truly useful tool, CM should not be carried out in isolation from maintenance, or without information to hand on the plant construction and production requirements.

CM can only inform effective Condition Based Maintenance (CBM) if comprehensive information is available to ensure the appropriate maintenance techniques are used, and if information on the results of corrective actions is fed back to the CM technician.

Factors such as fault and failure modes, criticality and cost-effectiveness all need to be considered, to avoid using the wrong CM techniques which may waste time, money and resources – and often with no discernible effect on improving or maintaining plant availability.

The virtuous circleThe condition based maintenance process is a circular one, driving continual improvement, as the diagram below demonstrates:

The steps in the red highlighted sections need to be in place before a CM provider considers making changes to an organisation’s maintenance regime. Without this data – and measurable uptime, availability, energy and throughput data – there is no benchmarking and therefore it will not be possible to measure improvements or return on investment.

Most organisations will know their critical plant and be aware of the cost of any loss of production. An experienced CM provider – such as ERIKS – will be able to help in identifying component parts and advising on criticality, but the customer will need to provide a failure/repair history, asset lists and downtime costs, as a mininum requirement.

Achieving maximum benefitWith the key plant and equipment identified and components logged, it’s time to review the maintenance tasks – ensuring they address the known failure modes. This means the engineering budget can then be applied in the best places and used in the best way to achieve maximum benefit for the customer.

Again, an experienced provider such as ERIKS will be able to deliver added value.

ERIKS Electromechanical Services, for example, have six key engineering core competences (Condition Monitoring, Electronics Services, Gearbox Services, HV Motors and Coils, Electrical Power Distribution and Pumps Services).

This means they have a history of known failure modes across all these areas, and will be able to apply the correct maintenance task – either eliminating the failure mode entirely, or increasing the mean time between repair or failure.

Where CM begins and endsThe specific Condition Monitoring aspect of the condition-based maintenance process takes place within the three steps in the tinted box.

It may require test equipment, online or portable data acquisition systems or embedded solutions. The data thus gathered and failure modes identified could then lead to asset repair or replacement, or engineering-out of recurrent issues.

A CM provider with all these capablities – such as ERIKS – will be able to provide solution-neutral advice aimed solely at the continuous improvement of a plant’s efficiency and productivity.

The final step before the condition-based maintenance process begins again is a joint review of the process to measure its effectiveness so far, and to identify the next level of improvements for the short- and long-term.

Adding valueWithout KPIs and SLAs as benchmarks, it is impossible to measure the effectiveness of any CM and CBM measures put in place. That’s why ERIKS offers an initial two-day CBM review before any site signs-up to an annual CM service. This enables accurate benchmarking and the provision of a road map with the best improvement routes highlighted.

To find out more, please visit www.eriks.co.uk/condition-monitoring

Condition Monitoring

DetermineMaintenance

Action

DataAcquisition& Analysis

SelectMonitoring

Methods

Cost/BenefitAnalysis

Review &Measure

Effectiveness

DetermineMaintenance

Action

DataAcquisition& Analysis

SelectMonitoring

Methods

SelectMaintenance

Tasks

EquipmentAudit

Reliability& Criticality

Audit

Cost/BenefitAnalysis

Review &Measure

Effectiveness

SelectMaintenance

TasksERIKS EMS

EquipmentAudit

Reliability& Criticality

Audit

30

The Tig

If you don’t switch it off, I can’t repair it!

“The latest Purchasing Manager’s Index statistics are a triumph for

British manufacturing. Hovering well above the 50 point barrier which signals growth, our industrial output has rarely been healthier in recent years.

Before we start getting over-excited, I just wanted to pour some cold water on all of this back-slapping.

My concern is that these numbers mask an uncomfortable truth, namely that British manufacturing is all-too-often operating its machines flat out. Like a car that is being thrashed up and down a motorway every day of the week, our packaging machines, conveyors, machine tools and lifting equipment are working 24/7.

This is good for output but bad for the machines. The old saying, ‘what you don’t repair you destroy’ has never been more apt.

The truth is that we aren’t doing enough repairs, or at least we aren’t doing enough of the right sort of repairs. Built-in redundancy time, which would give maintenance people the opportunity to dig a little deeper and identify whether a bearing is going to fail, or a spindle is nearing the end of its life or if a ball screw needs changing, is impossible if the machines are working flat out.

The root of this problem, I believe, is cultural. In the UK, management cannot stand to see a machine idle. Idle machines are by definition, non-productive and an eye-sore. Therefore, the only time maintenance engineers get access to a machine is when it goes down.

In Japan, the model is very different. In plants I have visited in the semi-conductor industry, fabrication equipment was only ever running at 60% capacity. One machine was always down for preventive maintenance with another one idle.

This meant that if there was a machine breakdown, the idle machine could be brought online and production continued. What’s more, it ensured that maintenance engineers could prioritise preventive maintenance work over breakdowns.

With maintenance teams already stretched, the key to implementing this sort of system is good vendor support, which allows in-house maintenance engineers to focus on preventive maintenance while vendor engineers pick up the firefighting.

This is not the cheapest option, but from my experience yield and uptime numbers were significantly superior in Japanese factories with this sort of system in place, compared to their British equivalents.

However, there is stiff resistance to this approach from most British managers. In-house maintenance teams plus vendor support is regarded as a ‘cost too far’. Attempts to implement more planned and preventive maintenance schedules, including condition and vibration monitoring, are therefore at the mercy of events and rarely survive the first major breakdown.

We wouldn’t expect a garage to perform an MOT while a car is running and we wouldn’t expect a repair man to sort out a washing machine while it’s in the middle of a rinse and hold. Why then do we expect our maintenance engineers to perform miracles?

There are some outstanding examples of highly efficient maintenance teams in the UK, leading the way in implementing state-of-the-art maintenance practices, but they are the exception rather than the rule.

My fear is that too many are operating on a wing and a prayer, hoping that machinery can keep going and firefighting when it inevitably fails.

“

ISSUE 22 www.eriks.co.uk/knowhow

Do you speak Fenner®?The Language of Power Transmission

THE LANGUAGE OF POWER TRANSMISSION

One Range, One Result, One Name

www.fptgroup.comGenerations of professional engineers have placed their trust in Fenner Power Transmission Products. This range has set the standard in performance to form the very foundation of their transmission drives. Put simply, the Fenner brand is “the mark of engineering excellence”.

So when engineers talk about a drive with Taper Lock® or Fenaflex™ tyre coupling, or any other of the key elements that make up the Fenner Power Transmisson range, they are speaking “the language of power transmission”. Shouldn’t you be speaking “Fenner”?

For Fenner, call ERIKS 0845 006 6000

Fenner is a registered trade mark of J. H. Fenner & Co.

Do you speak Fenner®?The Language of Power Transmission

THE LANGUAGE OF POWER TRANSMISSION

One Range, One Result, One Name

www.fptgroup.comGenerations of professional engineers have placed their trust in Fenner Power Transmission Products. This range has set the standard in performance to form the very foundation of their transmission drives. Put simply, the Fenner brand is “the mark of engineering excellence”.

So when engineers talk about a drive with Taper Lock® or Fenaflex™ tyre coupling, or any other of the key elements that make up the Fenner Power Transmisson range, they are speaking “the language of power transmission”. Shouldn’t you be speaking “Fenner”?

For Fenner, call ERIKS 0845 006 6000

Fenner is a registered trade mark of J. H. Fenner & Co.

Kill bacteria, not bearingsMaintenance-free, corrosion-resistant SKF Food Line Y-bearing units withstand frequent high-pressure washdownsHigh pressure washdowns are necessary to ensure hygienic conditions, but can quickly destroy mounted bearings. Thanks to the highly effective 2RF seal, SKF Food Line Y-bearing units do not allow water to enter bearings, eliminating the need for re-greasing after washdowns to “purge” water and contaminants. This common practice can damage the seal, enabling water ingress that causes bearing failure in as little as six months.

Pre-lubricated with NSF food-grade grease, these units are available in a full range of housing shapes in corrosion resistant composite material or stainless steel, with stainless steel and zinc-coated bearing inserts. Units have no grease nipples since no re-lubrication is required.

The resulting benefi ts can be many, from reduced maintenance costs and a safer workplace to elimination of re-lubrication and – as a result – reduced environmental impact.

Contact ERIKS, your SKF authorised distributor for details.

Engineered to withstand high pressure washdowns, SKF Food Line Y-bearing units feature a non-porous surface with no cavities to reduce risk of bacteria accumulation.

The Power of Knowledge Engineering

® SKF is a registered trademark of the SKF Group © SKF Group 2015

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eriks know+how magazine - issue 22

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