ERIKS Know+How Issue 18 - Food and Beverage

What’s eating you?
10 page focus on the problems and possible solutions
facing the food and drinks industry p12
A taste for efficiency
Bigger portfolios, lower costs p10
‘Wire to Water’ efficiency
A new whole-system
efficiency approach p22
Step this way
5 steps to
a smarter
storeroom
p24
Born or made?
What’s eating you?
RAGE
•FO
CUS ON
•
FO
O
D & BEV
E
RAGE
#*
The leading magazine for mainTenance engineers from eriKs
www.eriks.co.uk/knowhow
ISSUE 18
The engineers who’ll inherit the future p6

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3
Contents
Welcome To KnoW+hoW…
Bringing you the latest industry stories from around the world,
plus technology updates, features and comment. Our industry
focus this issue is the food and beverage sector, which,
according to a recent survey, must focus closely on reducing
waste to please its customer-base and strengthen consumer
confidence. As our editorial discusses, the need to reduce
waste is part of a wider awareness among the public that
sustainability in all possible forms is the future.
Practical solutions for the food and
beverage industry discussed this month
includes a piece on rocol (foodlube),
the first organisation in UK to add
metal detectable actuators and caps
to aerosol spray cans. meanwhile our
Planet+ feature discusses the benefits
of thermographic technology for the
food and beverage industry.
also this month we look at energy
saving, specifically drive system energy
losses and preventative action. There’s
a KsB pump article on cleaning in
Place (ciP), discussing the need for all
parts to allow unimpeded flow-through
and covering products that meet these
criteria, while sKf explains how
to keep machinery operational
in extreme temperatures.
if you have any issues you wish
to raise or comments to make
you can email the editor at:
knowhoweditor@eriks.co.uk, not
forgetting Know+how’s own website:
www.eriks.co.uk/KnowHow where
you can register for your own personal
copy and make enquiries about
something you have read or contact
one of the contributors.
I look forward to hearing from you.
Alan Whetstone
Managing Director, Editor in Chief
Published by eriKs UK, amber Way, halesowen, West midlands, B62 8Wg
UNREGISTERED
NEW QR CoDE ACCESS
To make it easier to get all the latest industry news
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LatESt NEwS 04food and beverage –
the top 10 trends for 2014
first pump auditing certification
liverpool to become a manufacturing
centre of excellence
4d printing technology goes composite
london’s Tube network transports
heat into homes
IN-DEpth 06Where are tomorrow’s engineers?
tEchNoLogy UpDatE 08eriKs acquires leader global Technologies
eriKs pump repairs make £4k annual
saving at UK auto plant
eriKs enhances customer service with
new marine appointment
new sealed sKf single row angular contact ball
bearings now available
Top 10 Tips for hose assembly
pLaNEt pLUS 10The recipe for efficiency
FocUS oN FooD & BEVERagE 12Waste not want not p12
savings in pints p13
raise a glass to KsB pumps p14
food and beverage processing?
it’s meat and drink to sKf p16
foodlUBe®
has safety in
the can p18
fresh from the festo factory p20
ENERgy SaVINgS 22saving energy from the ‘wire to
the water’
BESt pRactIcE 24step away from the problem
•FO
CUS ON
•
FO
O
D & BEV
E
RAGE

Latest news
ISSUE 18 www.eriks.co.uk/knowhow4
a recent survey has predicted that cutting waste
and building trust will be two of the key food
and drink industry trends of 2014. The top 10
predicted trends, from a survey by innova market
insights, will be as opposite:
The need to build trust has been fuelled by recent
food safety scares and scandals, which innova
says have crippled consumer confidence. This has
no doubt also increased scrutiny on the number
one issue – waste. The survey also identified that
consumers are now reassessing their needs and
going ‘back to basics’ by rediscovering the simple
pleasures of home cooking, while the rapid rise
of social media platforms is likely to propel more
small-scale innovators with high quality produce
into the limelight.
Food and
beverage
– the top
10 trends
for 2014
First pump auditing
certification
charlotte marsh has become the first ERIKS employee to receive
the new certified Pump system auditor (cPsa) qualification from
the British Pump manufacturers association limited.
To achieve her accreditation – designed to be a universally
recognised and respected industry standard for engineers who
assess the performance of pumping systems – charlotte attended
five days of courses. Three days were spent on a pumping system
requirements and analysis training course, followed by an exam.
one day covered energy assessment of a pumping system to
either asme ea2-2009 or iso 14414, and a further day was
devoted to a pump system optimisation course.
lastly, charlotte carried out a pump system audit and produced
an audit report, both in accordance with the relevant industry
standards. The report was then reviewed by an expert panel.
The new certification scheme aims to improve levels of
professionalism within the pumping sector, and is open only to
competent engineers who can demonstrate active involvement in
the industry. cPsa engineers must be re-assessed every three
years to maintain their certification.
The British Pump manufacturers association limited believes that
the new certification will help engineers become more effective in
their role, and show their employer’s industry leadership.
1. Waste not want not: cutting
food waste
2. You can trust us: improving
consumer trust
3. Simpler pleasures: back to basic
trends towards simpler food
4. Look out for the small guy:
small-scale innovators rise to
the challenge
5. Health is more holistic: a more
holistic approach in providing
nutritious food and beverage
solutions to consumers
6. ‘New’ superfoods
7. Rise of the hybrid
8. The Protein Horizon
9. New stealth strategies
10. Alternative alternatives

Latest news
5
liverpool is to develop a select range of
techniques to become a manufacturing
centre of excellence by 2020.
The plan is being mapped out by the
liverpool city region local enterprise
Partnership (leP) in consultation with
number of advanced manufacturing
partners in the locality and will focus
on the technologies of lightweighting,
non-invasive monitoring, shale gas
exploration and sustainable energy.
The initiative follows a current school of
thought that, in the global economy, the
best way to build manufacturing is to focus
on, and invest in, existing strengths and
establish centres of excellence to push
forward innovation. in its report, 'making
it: advanced manufacturing in liverpool
city region to 2020', the leP states: "a
manufacturing environment with four or five
clusters of excellence – with one frontier
industry – could provide a framework to
produce high value goods and services”.
an innovative heat recovery
scheme will provide warmth
for local homes by channelling
waste heat from london
Underground tunnels.
as anyone who has ever
travelled during rush-hour knows,
the london Underground system
generates large amounts of heat.
To put this energy to good use
(and relieve a few passengers)
warmth will be captured from a
northern line vent and piped into the heat network.
The project is a partnership between islington council, the mayor
of london Boris Johnson, UK Power networks and Transport for
london. The mayor of london’s senior advisor on environment and
energy matthew Pencharz said: "By supporting locally-sourced
energy and heat networks, which can reduce bills and lower carbon
emissions, we cannot only save money but also drive innovation,
jobs and growth in this burgeoning sector."
a team from the University of colorado
has developed and tested a method
of 4d printing that could advance the
use of adaptive, composite materials
in manufacturing and biomedical
applications. The concept allows materials
to self-assemble into 3d structures by
incorporating shape memory polymer fibres
into composite materials that can later be
changed to take on a new shape.
“in this work, the initial configuration is
created by 3d printing, and then the
programmed action of the shape memory
fibres creates time dependence of the
configuration – the 4d aspect,” explained
researcher martin dunn, from the singapore
University of Technology and design.
it is predicted that developments in 3d
and now 4d printing technology will help
create reversible or tuneable 3d surfaces
and solids in engineering, such as the
composite shells of complex shapes used in
automobiles, aircraft and antennae.
Liverpool to become a
manufacturing centre
of excellence
4D printing technology goes composite
London’s Tube network
transports heat into homes

In-depth
recent media interest began with a
double-whammy of attention-grabbing
soundbites. chief scientific advisor at the
department for Business, innovations and
skills – Professor John Perkins – warned
that the UK’s economic recovery could be
‘constrained’ by a lack of engineering skills.
at the same time, Business secretary Vince
cable claimed that a relatively low number
of young people were choosing to study
maths and science, in which ‘engineers
must have a strong foundation’.
With an acknowledged ageing workforce,
meaning vital skills and experience are
leaving the industry, it certainly looks grim
for engineering. and yet there are happier
headlines, successful initiatives, and plenty
of bright young would-be engineers slipping
into newly acquired overalls.
The best of the best
accredited as a Top employer by the
crf institute in 2013, ERIKS takes its
responsibilities for the future of the industry
very seriously. Which is why the company runs
not only an apprenticeship scheme but also a
graduate scheme. and their success is being
recognised beyond the business itself.
While the media were focusing on the doom
and gloom, two young ERIKS engineers
were making headlines of their own,
collecting a brace of awards.
Jacob Kane – an apprentice with ERIKS
chesterfield – was awarded apprentice of
the Year by the institute of engineering and
Technology, while fellow ERIKS employee
liam greveson won the first-ever exceptional
achievement award from the electrical
apparatus service association (easa).
Jacob was fully-funded by ERIKS to study
an electrical and mechanical engineering
BTec, on the ERIKS apprenticeship
scheme. ERIKS takes on 10-15
apprentices across the UK every year
for this 3-year scheme, which involves
24 weeks a year, 3 weeks at a time, at
loughborough college – one of the UK’s
leading universities for engineering and
technology. Then in addition, the apprentice
undertakes 40 weeks of full-time work in
ERIKS’ workshops.
liam had spent 7 years with ERIKS before
receiving his award from easa. he also
began as an apprentice, starting on the
shop floor as a Tester/fitter, and is now a
condition monitoring engineer.
his award from easa was presented to him
in Palma, mallorca, and he also visited two
easa member companies, including the
award sponsor: Karsten moholt as
of norway.
How managers are made
ERIKS’ graduate scheme – known as the
ERIKS UK academy – is a brand-new
initiative from ERIKS. it will undoubtedly
become another important contributor
WHERE ARE
ToMoRRoW’S
ENgiNEERS?
IF yoU LIStEN to oNE oF thE goVERNmENt’S aDVISERS – aND
INDEED to oNE oF ItS mINIStERS – yoU’D BE FoRgIVEN FoR
thINkINg that FRESh BLooD IS SEVERELy LackINg IN thE
ENgINEERINg INDUStRy. BUt IF yoU Look BEhIND thE hEaDLINES
at SomE oF thE BUSINESSES whIch aRE pLaNNINg FoR thE
FUtURE, thEN thE StoRy IS a VERy DIFFERENt oNE.

In-depth
7
of new blood to the industry, helping to
boost the UK recovery in the short-term,
and maintain and strengthen the country’s
engineering base in the long-term.
The scheme is currently in the recruitment
and selection stage for its first year’s intake,
but the intention is to take on ten graduates
for a comprehensive programme of learning
and development across the business UK-
wide, covering all divisions of the company.
The scheme lasts for two years and offers
three programmes, each one geared to
graduates in a different discipline: either
electro-mechanical engineering, general
engineering, or commercial Business and
management.
ERIKS’ learning and development
department will put together a full training
and development scheme for each
graduate, including a personal development
programme, and all the graduates will be
mentored by senior management and the
hr director. There will also be regular
performance reviews.
Planning for the future
The ultimate aim of both the apprentice
and graduate schemes is to recruit
quality candidates for ERIKS. successful
apprentices will go on to be employed
in hands-on engineering roles for
the company, but can also move into
management positions. graduates,
meanwhile, are specifically recruited for
eventual management posts. (see box-out).
so ERIKS’ drive to develop the engineers
of the future is not entirely altruistic. But
why would potential employees want to
work for ERIKS?
as europe’s leading industrial services
partner, the company offers the potential
of a rewarding career with a secure
future. But it’s more than that. The Top
employer accreditation from the crf
institute – an organisation that identifies
the top performers in human resources
– proves that ERIKS is committed to its
employees and their care and development.
The accolade recognised an outstanding
level of employee care by ERIKS across
several categories, citing the company’s
exceptionally high standards in categories
such as Working conditions, Training and
development, career development and
culture management.
By training, developing and
employing the best and brightest
talent of today, ERIKS aims to create
the best engineers of the future –
which will, of course, be good for
ERIKS. But it will also be good for
all of us within the industry, and
ultimately for everyone who will
benefit from a prosperous Uk.
Having joined a family business – subsequently taken over
by ERIKS – straight from University, I am in my 30th year with
the company.
I started as a Graduate Trainee in the Commercial
Department, managing National Agreements and customer
entertainment facilities, assisting in importing spare parts
from Germany and the USA, and acting as Quality Manager.
A secondment as a Sales Representative for a Service Centre
was followed by a period as Service Centre Manager. At 25
I became Commercial and Contracts Manager on the Board
of Management, then managed our German distribution arm,
subsequently returning as UK National Contracts Manager,
becoming a Director in 1995.
When the business was acquired by ERIKS I was appointed
European Key Accounts Director, before returning to my old
role in 2010. I am delighted to be part of a company with very
ambitious owners who can take a longer-term view.
David Arbuthnott
Corporate Key Accounts Director,
ERIKS UK

Technology update
8 ISSUE 18 www.eriks.co.uk/knowhow
ERIKS acquires Leader
global Technologies
ERIKS hAs Acquired All of The commerciAl AcTiviTies of leAder
GloBAl TechnoloGies (leAder), A leAdinG mAnufAcTurer And provider
of spirAl wound And meTAl GAskeTs for A vArieTy of indusTriAl
ApplicATions worldwide. leAder is heAdquArTered in housTon, TexAs
wiTh AddiTionAl operATions in BATon rouGe, lA And ByTčA, slovAkiA.
speaking on the acquisition, ERIKS ceo
Johan sleebus said, “The acquisition of
leader brings ERIKS a well-known brand
in a key product category. The company
manufactures high-quality products for
use in end markets that are at the core of
ERIKS’ global technical services strategy.”
leader has a well-established business
model of providing ‘engineered sealing
solutions through Partnered distribution’.
The company will continue to implement
this channel strategy on a global basis.
The leader Us operations will become a
part of the ERIKS north america business
while the Bytča, slovakia manufacturing
facility will become part of the ERIKS
european operations.
ERIKS pump repairs make £4k
annual saving at UK auto plant
ERIKS hAs cArried ouT A pump repAir plAn for A mAjor uk AuTomoTive
mAnufAcTurer ThAT hAs resulTed in An AnnuAl enerGy sAvinG
of ApproximATely £4,000. The plAn, which included pump repAirs
conducTed wiTh henkel, hAs Also Achieved A co2 sAvinG of 28
Tonnes in The firsT yeAr.
Work began when ERIKS evaluated
the efficiency of one of the automotive
company’s pumps. The pump in question
was a 22kW elPo, which handles process
water for a metalwork pre-treatment process
prior to body coating. The result of the test
was that the pump was found to be under-
performing by at least 30% against the
manufacturer’s original test data.
an estimated energy reduction of £3,936
was calculated for the first year alone
(calculated at £0.08/kWh at 12 hours per
day with an 80% load). it was therefore clear
that the cost of the repair, which amounted
to £5,542, would soon be recovered
and that substantial savings were to
follow. over a five-year period, this
accrues to a five-year energy saving
amounting to £19,680.
ERIKS enhances
customer service
with new Marine
appointment
ERIKS hAs enhAnced iTs offer
To mArine cusTomers wiTh
The AppoinTmenT of simon
hemper, mArine Business
developmenT mAnAGer.
simon’s depTh of experience
in The mArine indusTry will
Be exTremely vAluABle for
All cusTomers involved in
specifyinG mArine soluTions
To enhAnce efficiency And
performAnce.
simon has joined ERIKS from
aderco fuel treatment, and has been
appointed to develop and build on
ERIKS marine offer in response to
growing demand. With over 30 years’
experience in the marine industry,
simon has an outstanding track record
of achievements, including winning a
contract for equipment supply to four
P&o new build cruise ships worth
close to £2million.
ERIKS marine services include
overhaul and rewinding of generators
and motors, condition monitoring,
vibration analysis, thermographics,
dielectric loss analysis, and on-board
pump and gearbox repairs.

Technology update
9
New sealed SKF single row angular
contact ball bearings now available
skf hAs Announced ThAT iT hAs developed A new seAled sinGle row
AnGulAr conTAcT BAll BeArinG suiTABle for ApplicATions in mAny
indusTries, rAnGinG from pumps And compressors To GeArBoxes,
elevATors And elecTric moTors.
The new bearing features two non-contact
steel reinforced nBr (nitrile Butadiene
rubber) seals, and a high performance, long
lasting polyurea (gXn) grease as standard.
The non-contact seal lip design forms an
extremely narrow gap between the seal
lip and its counterface on the bearing
inner ring to exclude contaminants and
retain grease, even in applications with
vertical shafts. and because they are
non-contacting, the seals do not generate
frictional heat, which enables the bearings
to operate at the same high speeds as open
bearings. cooler operating temperatures
also extend the service life of the lubricant.
in comparison tests, sealed sKf single
row angular contact ball bearings operated
with 30% lower peak temperatures and
20% lower steady-state temperatures
than same-size bearings with contact seals
(values based on °c).
sealed sKf single row angular contact ball
bearings are dimensionally interchangeable
with open bearings and have the same high
load carrying capability.
1. Respect your hoses and fittings.
The incorrect selection of hose type could lead to catastrophic
failure and injury, as well as production down time.
2. Be aware of the dangers.
consider operational changes such as increased temperature,
pressure, or new chemicals, and how they will affect all the
process items such as the hoses.
3. consider newly enhanced components.
advances in technology have brought engineers the option to
specify bespoke industrial hose assemblies that are lighter and
stronger, and can meet the needs of many different applications.
4. match the fitting to the hose.
only by making the correct specification to match the hose
itself can engineers maintain the productivity and quality of the
hose output.
5. Specify correctly for low pressure.
careful specification and installation is required here, as
misalignment or over-tightening may cause leaks.
6. Specify correctly for high pressure.
in higher pressure applications, swaged or crimped connections
or lmc clamp fittings offer an excellent degree of security, giving
leak-free connections.
7. allow time for manufacture.
Whilst it is possible to manufacture, test and ship a hose the
same day, stock allowing, consideration should be given to holding
spares of commonly used hoses.
8. consider clamp fittings.
There are now some highly effective safety clamps on the market in
aluminium, brass and stainless steel.
9. operate a consistent maintenance programme.
The need to protect productivity, safety and profitability is
great in all applications but the issue can be critical in
certain industries.
10. consider a hose testing service.
ERIKS hose Technology offer a cost-effective hose testing
service, with hose assemblies being visually inspected, pressure
tested and checked internally with a ccTV camera.
for hose AssemBlyToP 10 TiPS10 T
For more detailed
information
scan this QR code

You and the
condition monitoring
tools, for example,
used to their full
capability, can
significantly improve
efficiency. a thermal
imaging camera is
capable of everything
from detecting a
damaged link in a drive chain generating
extra friction and heat, to evaluating the
effectiveness of doors and seals.
Thermography plays a vital role in monitoring
product quality in food production because of
the wide variety of temperature-controlled
operations involved. as a non-contact method
for monitoring and controlling ‘temperature
critical’ products, it is invaluable in the control
of cooking or sterilisation processes. it is also
becoming increasingly important throughout
the distribution chain for perishable food
materials, and for temperature control of
frozen and fresh food to help maintain
product quality and reduce safety risks.
Heat casts light
Thermal imaging cameras measure infrared
radiation, then represent temperatures with
colours on an lcd monitor. a thermographic
survey by an experienced and certified
operator is a swift and inexpensive condition
monitoring option, which can save thousands.
a recent thermal imaging survey by ERIKS
at the coors brewery in Burton cost less than
£1,000, yet highlighted potential savings of
around £60,000 per annum from a relatively
modest investment in repair work.
optical gas imaging cameras also use
thermographic technology, to detect leaks
– safely scanning thousands of components
per shift, with zero downtime. Because gases
are opaque in the infrared wavelength, the
cameras can ‘see’ the leak, and a trained
technician with a high-end camera can
detect more than 20 different toxic,
explosive and flammable gases – often
including those normally difficult to detect,
such as carbon monoxide.
Efficiency in store
sharper management of maintenance, repair
and operations (mro) procurement and
stores activity can also make significant
improvements in plant efficiency and
economy. accessible, well-organised stores
keep the factory floor running smoothly,
because engineers can quickly find the
equipment they need. a well-organised store
is also easier to manage because stock
replacement requirements are more visible.
ERIKS recently helped a major food
manufacturer reduce mro costs while
increasing productivity. Their paper-based
stores management system was replaced with
a paperless software solution, and barcoding
enabled the 7,500 stock items to be accurately
traced. The streamlined system also capitalised
on the data gathered to deliver a flow of
highly useful management information.
The above examples highlight some of
the ways plant engineers can reduce total
cost of ownership. By partnering with an
experienced solutions provider with
expertise in a range of technologies, food
and beverage manufacturers can maintain
product quality and variety in this
challenging economic climate, while still
managing costs.
cUStomERS oF FooD aND BEVERagE compaNIES aRE
INcREaSINgLy SEEkINg ShoRtER tURNaRoUND tImES FoR
EVER moRE compLEx pRoDUct poRtFoLIoS, to RESpoND
to VaRyINg maRkEt DEmaNDS. So maNUFactURERS NEED
aLL thE tooLS thEy caN gEt, to maINtaIN pRoDUctIoN
EFFIcIENcy aND maNagE coStS.
THE RECiPE FoR
EFFiCiENCY
thermographic
thermographic
Dave manning-ohren
condition monitoring
manager, eriks

Motivair is the UK’s largest independent compressed air management company, offering
a wide range of products and services for all the major brands of compressor:
• Planned maintenance and service plans
• 24/7 breakdown support
• Compressed air equipment, parts and accessories
• Consultancy, energy savings and lower costs
• ERIKS approved supplier
Motivair
ensures
continuous
compressed
air supply
No matter
what brand of
compressor
One call for all your compressed air needs.

Focus on Food and Beverage
in our news pages this issue we report on
a recent survey that has predicted, cutting
waste and building trust, will be two of
the key food and drink industry trends
of 2014. The phrase that tops the list of
ten predicted trends by innova market
insights is ‘Waste not Want not’, reflecting
manufacturers’ efforts to reduce food loss
or waste. “food loss during production and
food waste, at the retailer and consumer
end of the food-supply chain, will be
heavily scrutinised,” forecast innova, while
ingredients derived from the waste stream
were also said to hold big potential.
While the need to build trust has
been fuelled by recent food safety
scares and scandals that have
damaged consumer confidence, the
need to reduce waste is no doubt
part of a wider awareness among
the public that sustainability in all
possible forms is the future.
The food and beverage manufacturing
industry must now capitalise on new
technology to increase operational efficiency
and prevent wasted product. for example,
the potential to gather and share information
that is currently offered by barcodes and
sensors can be more fully exploited by the
engineering industry, particularly in the way
we manage our supplies.
efficiency has to improve and this will also
accelerate the need for more responsible
operations. The need to be more efficient
as a means of increasing profits goes
hand-in-hand with the growing change
in the attitudes of both engineering
companies and their customers towards
conducting more ethical operations. We
are moving towards a more responsible
industry, where specialists and innovators
are prized more highly than ever before.
The food and soft drinks industry is the
UK’s largest manufacturing sector and has
remained strong in the difficult economic
conditions that prevail, even as commodity
prices have climbed. one reason for this
is that, whatever the economic climate, we
tend to go on eating and drinking product
of one kind or another. however, it may also
have something to do with good installation
and maintenance. food processing
and packaging companies understand
more than most the vital need to protect
production and optimise productivity, and
ensure reliable predictive and preventative
machine maintenance programmes to avoid
delayed deliveries, wasted produce and
damaged reputations.
The continued success of the food and
beverage industry will therefore rely heavily
on both science and technology and,
of course, the ability to further increase
efficiency and product quality – all the
while adhering to stringent sustainability
guidelines. food and drink producers are
in the fortunate position of being able to
take advantage of ongoing developments
in processing technology and the need
to continually enhance the reliability of
processes cannot be underestimated.
paUL LyNch LookS at tRENDS IN thE FooD aND BEVERagE INDUStRy aND
why EFFIcIENcy LookS SEt to BE thE kEy DRIVER whEN It comES to
cUStomER SatISFactIoN aND pRotEctINg pRoFItaBILIty. paul Lynch
customer service director -
integrated solutions, ericks

13
thE DowNSIDE oF FREqUENt BEaRINg FaILURE IS
thE tImE, tRoUBLE aND ExpENSE oF DowNtImE, LoSt
pRoDUctIoN aND REpLacEmENt. thE UpSIDE IS that thE
moRE oFtEN It happENS, thE SooNER It wILL BE oBVIoUS
that thE FaILED BEaRINg IS a Symptom, Not a caUSE,
aND that It’S tImE to Look DEEpER INto thE pRoBLEm.
for engineers at a
milk processing plant
the realisation
came quickly, as the
bearing on one of its
conveyors was failing
every 10 weeks,
leading to downtime
of three hours every
time it happened. so
they called in nsK to solve the problem
sooner rather than later.
A tough job…
life for the bearing – and for the maintenance
engineer – was made harder by the bearing’s
inaccessible location. This made it difficult to
lubricate, which shortened the bearing’s life,
and then increased the downtime whenever it
needed replacing.
so nsK looked for a solution which not only
increased the bearing’s service life, but also
eliminated the need for lubrication.
The answer was life-lube®
stainless steel
bearing inserts, with molded-oil solid lubricant.
These are available in Pillow Block, 2- and
4-bolt flanges and take-up unit housings, with
bore sizes from 20mm to 40mm.
More life, less maintenance
The new bearing brought multiple benefits
to the application.
not only did it extend bearing life – from
10 weeks to more than 12 months – but it
also eliminated the need for lubrication
maintenance during its lifetime. in addition,
when the bearing finally did require
replacement, its design meant there was
no need to replace the bearing shaft – unlike
with the previous type of bearing.
The longer service life was partly due to the
PBT thermoplastic resin housing of the new
bearing, which is corrosion resistant. The
housing also has the added benefit for food
and beverage applications that it is paint-free:
meaning no chipping or flaking, and no risk of
contamination of the process.
made from martensitic stainless steel, with
nitrile rubber seals, the bearing is also
resistant to contamination, making it ideal for
operations where process fluid is unavoidable.
Milking the savings
as well as identifying the cause of the
bearing failure – insufficient lubrication due
to inaccessibility – and recommending the
life-lube®
housing and molded-oil insert
to resolve it, nsK also provided expert
technical support for fitting of the new
life-lube®
units.
The end result of changing the existing
bearings for the nsK solution, was significant
cost savings for the customer, delivered to
their doorstep.
EXiSTiNg CoST P.A. NSK SoLUTioN CoST P.A.
old bearing design: €140 new bearing design: €136
lab: 2 fitters × 3 hours @ €25/h, 5 × year €750 no maintenance €0
downtime: 3 hours @ €2.055, 2 × year €12,330 no downtime €0
2 x shafts replaced @ €110 each €220 no replacement shafts €0
Total cost €13.440 Total cost €136
kevin Delehanty
senior Applications engineer
nsk

BEER DoESN’t jUSt NEED hopS, watER aND yEaSt. It aLSo
NEEDS RELIaBLE pUmpS at EVERy StagE FRom BREwhoUSE
to BottLINg. kSB haS BEEN SUppLyINg thE NEcESSaRy
EqUIpmENt SINcE 1871, FoR pRImaRy pRocESSES aND FoR
cooLINg, watER tREatmENt, waStE watER tRaNSpoRt
aND othER SEcoNDaRy cIRcUItS.
dependent upon the yeast viscosity, KsB
Vitacast centrifugal or Vitalobe rotary lobe
pumps can be used in yeast cellars. however
the Vitalobe handles the higher viscosity
whilst still handling the shear sensitive
product. a gap between rotor housing and
bearing bracket protects pump and fluid from
excessive heating and prevents lubricant
from contaminating the fluid. There is also
a choice of mechanical or shaft seal sealing
rings – with or without a flushing device – for
the shaft passage through the rotor housing
of the Vitalobe.
Tailored to the application
after storage and maturation, the filtration
process also use pumps, and KsB offers a
range of suitable models from Vitachrom and
Vitacast to Vitalobe and Vitastage.
finally, the bottle, drum or keg filling station
is the most demanding location for hygiene.
low inlet pressures and beverage blending
systems operating under vacuum conditions
add to the challenge the pumps face. such
applications call for european hygienic
engineering & design group-certified,
single-stage centrifugal pumps such as
Vitachrom, which offer 13 different sizes
and flow rates up to 340m3
/h, so it can be
optimally sized to meet requirements.
The back pull-out design and stub shaft
means that pump and motor each have their
own shaft, making these pump sets highly
maintenance-friendly.
Cheers!
Beginning in the brewhouse,
processes are sterile so pumps
must be manufactured from
certified materials that can be
cleaned and sterilised in place.
cleaning in Place (ciP) requires all
parts to allow unimpeded through-flow,
with little dead volume, smooth-as-
possible surfaces, and gapless,
easy-to-clean casings. Pumps must
also be fully resistant to cleansing
media and high temperatures, with
o-rings open and arranged directly
toward the product. Back vanes
on a semi-open impeller enable
good circulation around the
mechanical seals.
single- or multi-stage etanorm or
movitec pumps are used to transport the
water to the mash tun, where milled malt
is mixed with brewing water and enzymes
to produce the wort.
The lautering process uses single stage
pumps, such as stainless steel etanorm or
Vitachrom models. Where the fluid mixture
contains gas or solids, the Vitachrom with
its open impeller expels residual oxygen
and can handle products containing solids
without clogging. The wort is initially more
viscous, so for smooth handling the pumps
must be precisely tailored to suit the
operating conditions. it is then boiled in a boil
kettle, requiring a powerful pump to circulate
the kettle contents eight to ten times an
hour throughout the process.
Easy on the fluid
after cooling, the wort is oxygenated, and the
Vitaprime is ideal for handling the gas laden
liquid – designed for continuous operation
at temperatures up to 140°c and a rated
pressure of 10 bar.

ADVERT
WEG
RAiSE A gLASS To
KSB PUMPS
Motors | Automation | Energy | Transmission & Distribution | Coatings
Are you ready
for the change?
European Directive 2005/32/EC states that from January 2015
all motors with a rated output of 7.5kW – 375kW shall meet the
level of IE3 or IE2 when driven by an inverter.
At WEG, we offer both IE3 and IE4 efficiency level motors in
standard IEC frame sizes. WEG also offer a complete range of
VSD’s ensuring that not only can you meet the legislation, but
keep both your CO2 emissions and running costs to a minimum.
WEG, energy efficiency as a standard not an option.
For information on how to make the change,
visit www.weg.net/uk

There are some industrial environments
which offer the same extremes of
temperature found in food and beverage
facilities. some may be equally moist, and
prone to contamination. some may even
have as many washdowns which can
degrade equipment and potentially cause
lubricant leakage. some may also involve
repetitive tasks in hazardous working
environments. But there are not many
industries where all these factors are
combined to make life hard for equipment
and its components.
But that’s not all the food and beverage
industry has on its plate. There are also
the pressures that you can blame on the rest
of us: the consumers.
ever more picky and particular, with
ever-changing tastes and preferences,
we continually demand new food and
beverage sensations, which means
manufacturers are continually placing new
demands on their equipment and technology,
which have a knock-on effect on the
machinery and productivity.
Then, last but not least, all these pressures
have to be addressed while trying to reduce
prices, but without cutting corners on
meeting strict health, food safety and
environmental legislation. so with rising costs
for energy and labour, it’s clear the need to
optimise equipment reliability and maximise
uptime and productivity is greater than ever.
From field to fork
over the decades, sKf has worked
alongside companies from almost every
sector of the food and beverage industry, at
every stage of production and at every point
in the supply chain.
from national and multi-national soft drinks
producers to major UK bakery companies;
from frozen food producers to makers of
salads and ready-made sandwiches; from
brewers and distillers to confectioners and
crisp makers – sKf has worked with them
all. and from growers and farmers through to
processors, manufacturers and packaging
and labelling companies.
so naturally sKf know and understand the
problems they face, the restrictions and
legislation that they have to comply with, and
the environments in which they have to work.
When the going gets tough…
The tough conditions in which the industry
operates – which prove such a challenge for
all kinds of equipment and manufacturers
– have driven sKf to develop new and better
bearing solutions for the entire food and
beverage production process.
sKf has dealt with equipment involved in
preparation, heating, cooling, and post-
production packaging: from ovens, conveyor
systems and provers, to bottle-fillers,
homogenisers, freezers and fryers.
as a result, the company has built up
unparalleled expertise in the areas of
bearings, seals, lubrication, mechatronics and
services for this industry, and can provide
suitable solutions for any food or beverage
manufacturer or processor. now their
knowledge and experience of the industry
allows them to deliver a number of important
benefits, including:
Increasing mean time between
equipment failures
Increasing efficiency and
maximising output
Improving hygiene by eliminating
conditions that foster food-borne illnesses
Reducing risk of injury to operators and
maintenance staff from repetitive tasks,
heavy loads, and slippery or potentially
hazardous environments
IF yoU haD to DESIgN thE pERFEct tEStINg gRoUND to pUt
EqUIpmENt thRoUgh thE toUghESt chaLLENgES, yoU
coULD Do a Lot woRSE thaN BaSE It oN thE opERatINg
coNDItIoNS FoUND IN thE FooD aND BEVERagE pRocESSINg
INDUStRIES. So whEN yoU’RE LookINg FoR BEaRINgS to
opERatE IN thIS ENVIRoNmENt, yoU caN’t aFFoRD to chooSE
aNythINg LESS thaN thE BESt. David oliver
Global food & Beverage
segment manager, skf
FooD AND BEVERAgE PRo
it’s meat and d

17
Watch your waste
sKf can also help producers and
manufacturers meet the requirements for
iso 22000 on food safety, and satisfy
increasingly tough environmental legislation
by reducing waste, cutting down water and
lubricant usage, and minimising the impact
of washdowns on local ecosystems.
They can provide nsf-approved food-safe
lubricants, and have the knowledge and
expertise to allow food and beverage
organisations to improve the efficiency of
machinery and auxiliary equipment, from
electric motors and pumps to ovens and
refrigeration systems.
Maintenance meltdown
An ice cream manufacturer came to
skf with a problem caused by the
main gearbox and chain drive in one
of their hardening tunnels. They were
scheduling maintenance every 12
months to avoid catastrophic failure.
skf conducted a root cause failure
analysis, which revealed an issue with
the ‘breathing’ of the gearbox, caused
by air expansion behind the seals,
leading to water ingress.
The sub-zero temperatures required
for freezing, chilling and cooling
processes demand frequent
maintenance. during cleaning,
temperatures can change rapidly –
leaping from sub-zero to 35°c –
causing air to expand within the
bearing and leading to ‘breathing’
problems. This allows water or
moisture to enter the bearing,
resulting in corrosion and lubricant
contamination and degradation which,
together with frozen water and other
factors, can lead to premature bearing
and seal failures.
skf recommended skf stainless
steel deep groove ball bearings with
food Grade solid oil, a cartridge
arrangement containing ecoflon 4
seals, and a flinger outboard of the
gearbox vertical output shaft. As a
result, the ice cream manufacturer has
been able to increase mean time
between repair to 18 months.
You can find out more about sKf’s solutions for the food and Beverage industry at
www.skf.com/uk/industry-solutions/food-and-beverage
It’s sure to give you plenty to chew over.
oCESSiNg?
drink to SKF

rocol, the leading UK food-grade
lubricants manufacturer, has become the first
in the UK to add metal-detectable plastic
actuators and caps to its aerosol spray can
packaging. These innovative features
massively reduce the risk of foreign object
contamination during food and drink
processing because – unlike traditional
actuators and caps – they can be detected
using the standard metal detection
equipment installed in many food and drink
processing plants.
if they become loose in food and drink
processing areas, the patent-pending
deTeXTm
caps and actuators – now used on
all foodlUBe aerosol cans – can be
quickly identified and removed. so production
downtime is minimised, and the risk of batch
contamination is reduced or eliminated.
not only are the components easily
detectable, but they are also manufactured
from safe materials deemed acceptable by
the Us food and drug administration for use
in food processing plants. and of course,
foodlUBe itself has a long-standing nsf
registration, and rocol has corporate
iso 21469 certification – both of which
offer crucial safety assurances about
lubricant formulation.
A cap on downtime
rocol marketing manager Joanne
ferguson explained that, “the addition
of deTeX caps and actuators represents
another important step in helping food
and drink processors avoid costly
downtime, product recalls and the risk
of reputational damage.
“We are continually looking at
new ways to help address safety
risks, and this includes utilising
new technology like DETEX
wherever possible. Our corporate
strength as part of the global ITW
Group gives us privileged access
to developments of this kind.”
foodlUBe products are available for a
wide range of applications across processing
plants in the food, drink and clean industries.
The foodlUBe aerosol product is a chain
lubricant, which is ideal for lubrication of all
types of drive and conveyor chains. its
outstanding penetration properties ensure it
lubricates where it’s needed, and it goes on
lubricating for longer thanks to its high
resistance to water wash-off, and its water
displacing properties.
The lubricant, which has a tenacious low drip
formulation and good load carrying capacity,
operates in the temperature range –20°c to
+150°c (+180°c for short periods). like all
foodlUBe products it is nsf h1
registered, which means it has been
independently assessed and deemed safe
for processing equipment used to produce
food and drink for human consumption.
foodlUBe chain fluid and foodlUBe
extreme food grade grease – for extremely
wet applications – are also available.
USINg FooDLUBE FooD-gRaDE LUBRIcaNt FRom RocoL IN
FooD aND DRINk pRocESSINg appLIcatIoNS IS Now SaFER
thaN EVER. BEcaUSE Not oNLy IS thE LUBRIcaNt aS SaFE
aS It’S aLwayS BEEN, BUt Now ItS packagINg IS SaFER too.
FooDLUBE®
has safety in the can

19
Performanceyoucantrust
PATENT PENDING
One more step in food safety. ROCOL®
, the UK’s first
ISO 21469 Certified lubricants manufacturer, launches
unique DETEX™
Technology. DETEX™
metal detectable
components are designed to assist food processing
plants in meeting strict HACCP requirements.
METAL
DETECTABLE
PLASTIC
COMPONENTS
ROCOL FOOD SAFE MAINTENANCE AEROSOLS
Visit www.rocol.com or call +44(0)113 232 2600 for further details ISO 21469 Certiﬁed

It takES oNLy oNE SmaLL BUt cataStRophIc LapSE IN hygIENE StaNDaRDS
to RUIN a BRaND’S REpUtatIoN. howEVER, It takES oNLy oNE EFFIcIENt
maNUFactURER oF cUStomER SoLUtIoNS to pLay a cRItIcaL RoLE IN
pREVENtINg pRoBLEmS, aS wELL aS INcREaSINg VaLUE cREatIoN IN FooD
aND BEVERagE maNUFactURINg. that oNE maNUFactURER IS FESto.
andrew macpherson
industry segment manager
GB food and Beverage
industry
Fresh from the

21
cost-efficiency and consistently high
hygiene standards are always going to be
priorities for automated food production.
But with increasing demand for product,
packaging and pack size variation, there’s
a need for fast set-up times and a high
degree of modularity in production plant too.
fortunately, through single sourcing, process
and factory automation technology from
festo, food production can be made more
efficient and still stay safe.
Automation everywhere
festo products have a place at most
stages of the food production process,
where their efficiency, hygienic standards
and resistance to harsh environments make
them indispensable to safe productivity.
for continuous production processes –
like mixing and stirring, sterilisation,
pasteurisation, homogenisation, filtration,
dosing, weighing, filling and storage –
automation means reliability. semi-rotary
actuators and linear drives open and close
process valves throughout the plant, and
high quality air preparation (defined by iso
standards) also plays an important role in
ensuring hygiene and extending the reliability
and life of the control system.
in the splash zone of food processing
operations, automation equipment doesn’t
come into contact with food. But corrosion-
proof design is mandatory, as water splashes,
cleaning agents or dripping food may
damage drives and valve terminals, proximity
sensors and fittings.
With decentralised control, splash resistant,
clean design valve terminals (cdVi) and
individual valves (cdsV) can be considered
for installation close to the drives, with no
need for a protective control cabinet. clean
design (cdc) cylinders are designed without
sharp edges or corners, ensuring that dirt
residues or germs can be completely
removed during cleaning. When additional
guidance is needed, guided cylinders
(dgrf) are available.
a very useful dry running seal option prolongs
the life of actuators even when the grease
inserted during manufacture is completely
washed away – usually the death knell of an
actuator. naturally, cylinder lubrication and
seals have fda certification, and the
accessories – such as proximity sensors – are
optimised for the environment, and resistant to
cleaning agents, heat and mould.
Tough cookies
When the cooking gets tough, you need
a tough and reliable performer.
ideal for food zones is the festo stainless
steel roundline iso cylinder (crdsnU). its
gently rounded profile makes it easy to clean,
and its unique, self-adjusting end position
cushioning saves time during set-up and
maintenance.
for harsh environments, users can choose
seals from a range of festo modular seals.
These include fda-compliant seals for food
use with standard cleaning regimes, and
seals for unlubricated and intensive cleaning.
fKm seals are available for elevated
temperatures up to 120°c and acidic
environments, while there are hard scrapers
for temperatures down to –40°c and for
harsh applications as varied as sugar crystals,
honeycomb and icy fish scales.
End of line packaging
for the non-food zone, festo provides
a wide variety of handling solutions, with a
choice of drives to meet individual customer
applications in packaging, labelling,
testing and monitoring.
our handling experts can select from
more than 30,000 standard products and
use either servo-pneumatic, electric or
pneumatic technology to suit the customer
application. systems are delivered fully
assembled and tested as ready-to-install
solutions. This means not just the hardware
but a complete value creation package, with
less work for the customer, reduced system
design costs, simplified procurement and
lower process costs.
“Fit and forget is the
objective for our
customers,”
explains andrew macPherson, industry
segment manager for the gB food and
beverage industry. “no two handling systems
are the same. They vary from simple
pick-and-place systems to linear and
cantilever gantries, 3d gantries, dual rod,
and kinematic Tripod robotic systems.
“our customers describe their handling
task, we deliver a plug-and-work solution
directly to the installation cell, and there is
no need for complex commissioning,”
continues macPherson.
Putting an end to waste
many companies have declared war on waste,
with high energy prices increasing the focus
on energy reduction. less machine downtime,
and the detection and elimination of leaks in
compressed air systems, are crucial.
That’s why total productive maintenance,
condition monitoring and energy-
saving services are key factors in food
processing plants.
food safety and energy efficiency are not
mutually exclusive. on the contrary. While the
use of hygienic automation technology from
festo helps food remain fresh, so the plants
in which it is produced stay fresh and modern
– with state-of-the-art festo technology.
Festo factory

Energy savings
As a result, alongside increasing efficiency
in electric motors, a new whole-system
efficiency approach is now emerging, best
known by its pumping sector description of
‘wire to water’.
Laying down the law
legislation is forcing increases in industrial
electric motor efficiency. under the eu
meps (minimum efficiency performance
standard) scheme, from 1st january 2015,
newly manufactured 7.5kw and above ie2
rated motors must have variable speed drive
(vsd) control, and uncontrolled motors must
have a minimum ie3 rating.
with ie3 at the upper limit of induction motor
efficiency, manufacturers are anticipating ie4
and above with various new technologies.
A popular option is motors using high
powered “rare earth” magnets, but the
raw materials’ cost makes this technology
expensive. various attempts at lower cost
solutions have been developed, for example,
the notable launch of the synchronous
reluctance motor from ABB, which in
common with the permanent magnet motors,
requires a dedicated vsd to operate it.
Brazilian manufacturer, weG have an already
proven premium efficiency motor which
meets the criteria for ie4. This American
market ‘nemA’ specification motor uses a
conventional design, so does not require any
specialised vsd for operation.
Driving savings
no other technology can deliver the energy
savings made possible by reducing the
running speed of motor-driven equipment
than vsds. so development of this
inherently efficient technology has
focused on ease of use and performance.
however, in the uk market, the carbon
Trust energy Technology list – itemising
specific technology eligible for enhanced
capital Allowances – now places more
stringent requirements on vsd technology.
The fenner qd series of vsds retained
its status on the list thanks to its energy
optimiser function within its general
purpose controllers.
electrical regulations amendments for
limiting harmonic distortion have also
pushed vsd development towards
mitigation of distortion, but most filtering
solutions increase the losses in the drive.
As an alternative, the fenner qd:hvAc will
soon introduce film capacitor technology,
addressing the cause rather than the
symptoms of distortion, with a slight
increase in efficiency to boot.
The right gear
The equipment coupled to a motor’s shaft
varies widely. many systems employ a belt
drive to transmit power from one shaft to
another. Advances in v-belt and wedge
belt technology have led to a five-fold
liKe The old song aBoUT The Knee Bone connecTed To The
Thigh Bone, eVerY elecTric moTor is connecTed To machinerY.
and no maTTer hoW clean, comPacT and efficienT The moTor,
WhaT iT’s connecTed To maY noT Be.
SAViNg ENERgY
FRoM ‘THE WiRE
To THE WATER’
mark maher
Technical manager
eriks uk, Technology
centre - drives

Energy savings
23
increase in the power a single belt can
transmit, and reducing the number of
belts required naturally increases a
drive’s efficiency.
synchronous belt drives are even more
efficient, but not always the most suitable –
if noise is a concern, for example. The drives’
efficiency depends on correct installation,
with particular reference to pulley alignment,
belt tensioning, and the condition of the
pulley grooves.
Gearboxes are often employed to convert
the motor shaft’s high speed into more
usable high torque, lower speed motion.
worm gears have been favoured for their
compact size, and low initial cost, but this is
negated by the high running cost compared
to the equivalent helical gear train.
of course, for any mechanical system,
correct shaft alignment is key for
achieving the potential efficiency.
misaligned shafts will increase bearing
loads and fatigue stresses within the
machine – not just using more energy,
but also reducing service life.
Exceptions to the rule
centrifugal pumps and fans are a unique
equipment category, because their output
is not uniformly related to shaft speed.
instead, fluid pressure and shaft torque
vary with shaft speed.
The ‘cubed law’ states an approximate
cube relationship between shaft speed and
power requirement, which is true for fans
and for pumps which do not have to lift the
fluid very high. conversely, for a pumping
system moving water to a height, the
reduction in pressure eventually becomes a
problem when there is not enough pressure
to lift the water, so no flow. A simple test is
to compare the pumps’ nameplate pressure
with the actual pressure required. if there
is excess pressure, large savings can be
made, but where the two parameters are
close, a speed reduction will soon result
in no flow.
Adjusting pump and fan speeds to match
output to demand – especially where
demand changes – is a great way to save
energy. it is often implemented using
sensors and automatic control, which is
now a standard feature in most vsds.
‘Wire to Water’ efficiency
This measure of system efficiency can be expressed in
many ways, depending on the process. for example, a water
pumping station would be measured by the cost of moving a volume of water
(kilowatts per mega-litre per day).
however, looking purely at whole-system efficiency is not always a fair
representation. after all, businesses pay for energy used, not for efficiency. for
example, where a pump system has a 20% higher flow than required, assuming that
there is adequate pressure, it would be valid to reduce the pump speed. even if we
account for additional losses by introducing a Vsd, and perhaps a pump efficiency
reduction at the new operating point, it would still use less energy and therefore cost
less. This is where absorbed power is dominant.
Numeric notes
overall system efficiency
is the numeric product of
the component efficiencies.
That is, each component’s
efficiency must be
multiplied together. This
can create a surprisingly
low overall efficiency, as
shown below:
VSD (98%) *
Motor (88%) *
Gearbox (95%) *
Pump (85%) =
69.6% SYSTEM
EFFiCiENCY

Best practice
Stock aND StoRERoom maNagEmENt DoESN’t jUSt aFFEct yoUR StoRES. yoUR SUppLy chaIN caN taNgLE
Up yoUR whoLE BUSINESS. aND pURchaSINg caN coSt EVERyoNE. kNock-oN EFFEctS FRom thESE aREaS
aRE FELt RIght acRoSS yoUR BUSINESS’S EFFIcIENcy, pRoDUctIVIty aND pRoFItaBILIty. BUt aLL yoU haVE
to Do IS StEp away FRom thE pRoBLEm – wIth thESE FIVE StEpS that REpRESENt BESt pRactIcE.
Step away from the
PRoBLEM
1What’s what,
and where is it?
A part by any
other name2critical parts need to be clearly identified
and stored where your engineers can
find them, quickly and easily. otherwise,
a breakdown can become a major
downtime disaster.
There could be a number of reasons
why your critical parts are not currently
easy to find. it could be because no-one
has ever bothered to identify which are
critical and which are not. or perhaps
when they’re delivered, there’s no proper
process in place to receive them, identify
them, label them and store them away in
the right place.
sort out those issues and you’ve taken the
first step towards a better organised, more
efficient storeroom – and a more efficient,
more productive plant too.
one man’s 200mm pneumatic cylinder is
another man’s ‘machine one Thruster’, and
another’s ‘part no. dnc 100-200’. which
is fine when the first man’s pneumatic
cylinder is in stock when he needs it. not
so fine if a different engineer needs the
same part, but knows it by a different
name, thinks it isn’t in stock, and orders a
new one. And so on, and so on.
you could end up with three times as
many parts as you need, each one only
accessible by the engineer who ordered it
and named it. And if some of the over-
stocked parts are left unused because the
first engineer doesn’t know they are there,
they could become unusable through age
before anyone discovers them.
The simple step to take is to name parts
consistently, and ideally with a name which
contains all the important information (such
as: ‘cylinder, pneumatic, 100mm bore,
200mm stroke’).
all too often, storerooms
contain more than
just parts and supplies.
Somewhere in the
chaotic, mismanaged
depths, they’re also
storing up trouble.
it may be when there’s a catastrophic
machine failure and a critical part isn’t in
stock. it may be when an audit discovers
money has been wasted re-ordering parts,
when there are still several in stock – just
wrongly labelled. or perhaps when the
right part is in stock in the right place, but
because it hasn’t been stored and cared
for correctly it’s unserviceable.
or maybe there won’t ever be a ‘lightbulb’
moment (or a ‘need a lightbulb and there
isn’t one in stock’ moment). instead, you’ll
just wonder why a simple maintenance
job takes longer than it should, why
your engineers are spending less time
engineering and more time sourcing
supplies, and why productivity is slowly but
surely falling.
That’s when it’s time to start taking five
simple steps to address the problem.

Best practice
25
Supply chain
or millstone?
one step,
less walking
Talk your way
out of trouble3 4 5The more suppliers you have, the more
resources you tie up in managing an
unwieldy and inefficient supply chain.
in fact, if your business is anything like
average, 65% of your purchasing resource
will be dedicated to controlling just 10% of
your purchases – usually your mro spares.
however, if you take the important step
of consolidating your supplies with one
vendor, you not only reduce the resources
needed to manage the supply chain,
but you can also realise numerous other
benefits. such as raising fewer purchase
orders (at an estimated cost of £50 each),
paying fewer invoices, and incurring lower
or no carriage costs.
And the more experienced and efficient
the supplier – with knowledge beyond
the storeroom – the more opportunity you
have to realise even greater efficiencies in
your wider organisation. especially if you
locate the supplier’s representative on-
site, for instant access and support that’s
always available.
some engineers may look like humans, but
they’re actually squirrels – storing parts in
their own secret stash, so they don’t have
to deal with lengthy walk-and-wait times or
poor service from a mismanaged storeroom.
it’s an unorthodox solution but in many
ways it’s the right one. so what you need
to do is take the step of legitimising it and
controlling it, by providing an authorised
‘secret stash’ in the form of a lineside
vending solution.
you know what stock is where, who
accesses it and when. downtime is
minimised. And your engineers become
human again. Though they may be even
more bright-eyed and bushy tailed.
The final step away from the problem is
to talk. Talk to the people who deal with
stock and storeroom management all day
every day, and who also know something
about your business – because they deal
with that every day too. in other words:
your suppliers.
Talk to them about all the other steps above,
and you may find they are the ones who can
help you to achieve them all successfully.
But make sure you talk to a supplier who
has knowledge beyond the storeroom. who
has application, engineering and technical
know-how. who has mro expertise, and a
process re-engineering capability. And who
can deliver benefits you’ll see quantified with
signed-off cost savings.
In fact, talking to ERIKS could
be a step in the right direction.
knowhow.eriks.co.uk/onsite
julia mullar
operations development
manager
eriks uk
integrated solutions

“
as reported in our news pages, we
are ‘heading in the right direction’
when it comes to apprenticeships. for
example, the department for Business,
innovation and skills is making available
nearly £49m to boost engineering skills,
with the majority of the funding made
available to allow employers to bid for
match-funding for training schemes that
will address specific engineering skills
shortages.
most of us would agree that we need to
inspire and support a new generation of
engineers here in the UK but the question
is, how? We’re doing our best to inspire
young engineers: two high-achieving young
employees have recently collected awards,
highlighting the success of our ongoing
apprenticeship programme and showing the
rewards that can be reaped – for employer
and employee – by investing in talent.
ERIKS chesterfield apprentice Jacob Kane
has been awarded the title apprentice of
the Year by the institute of engineering and
Technology, while colleague liam greveson
won the first ever easa (electrical
apparatus service association) exceptional
achievement award. meanwhile, the debate
over how to encourage engineering talent
continues to generate opinion, debate and
plenty of statistics. concerned that the
UK will require 2.2 million employees over
the next five to 10 years, The engineer
columnist Paul Jackson looked at attitudes
to engineering within the education system
back in 2012. Jackson discovered that one
in five science, design and technology, and
maths teachers surveyed by the magazine
say they believe a career in engineering is
undesirable for their students. however,
by 2013, The engineer reported that almost
a third of parents, who had previously
dismissed apprenticeships as a viable
career choice, had changed their views.
a survey commissioned by Bae systems
and the royal academy of engineering
and carried out by Yougov canvassed
2,000 parents of children aged 11-18.
it found that 42% had gained a more
positive view of apprenticeships in the last
year; 29% said they saw such schemes
as a viable option for their own offspring
but would never have considered it five
years ago. (it also found parents on higher
incomes were more than twice as likely
as those with average incomes to see
apprenticeships as good for other people’s
children but not their own.)
With a strong predicted demand for
engineers, perhaps the careers service
can help identify potential and promote
engineering as a profession? and when
we do get apprentices, can we do more
to inspire them? We need to make the
most of their skills and support personal
development so that apprentices truly
feel involved. in doing so, those already
established in the business can help
themselves.
When the business suffers from a
skills shortage, it’s middle managers
that have to step in and sort things out.
As this experienced workforce grows
older, it is they who will bear the most
stress. So, the sooner we recruit,
inspire and keep a new wave of
apprentices, the better.
The Tig
More
apprentices,
less stress
“

ADVERT
NSK UK Ltd · Northern Road, Newark, Nottinghamshire, NG24 2JF · Telephone +44 (0) 1636 605123 · info-uk@nsk.com
Total Quality by NSK: The synergies of our global network of NSK Technology
Centres. Just one example of how we meet our requirements for high quality.
NSK is one of the leading companies with a long tradition in patent applications for
machine parts. In our worldwide research centres, we not only concentrate on the
development of new technologies, but also on the continual improvement of quality
based on the integrated technology platform of tribology, material technology, analysis
and mechatronics.
More about NSK at www.nskeurope.com or call us on +44 (0) 1636 605123
NSK UK Ltd · Northern Road, Newark, Nottinghamshire, NG24 2JF · Telephone +44 (0) 1636 605123 · info-uk@nsk.com
Total Quality by NSK: The synergies of our global network of NSK Technology
Centres. Just one example of how we meet our requirements for high quality.
NSK is one of the leading companies with a long tradition in patent applications for
machine parts. In our worldwide research centres, we not only concentrate on the
development of new technologies, but also on the continual improvement of quality
based on the integrated technology platform of tribology, material technology, analysis
and mechatronics.
More about NSK at www.nskeurope.com or call us on +44 (0) 1636 605123
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ERIKS Know+How Issue 18 - Food and Beverage

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ERIKS Know+How Issue 18 - Food and Beverage