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The BBA has just taken delivery of a new rig which tests the hygrothermal performance of solid wall insulation systems called external thermal insulation composite systems (ETICS) to the European Technical Approval Guideline (ETAG) 004. ETICS are external wall insulation systems (EWIS) comprising insulation coated with render. The new rig is extremely versatile and can meet the requirements of a number of different test specifications.

The ETAG 004 test regime involves subjecting an insulated solid wall to a series of extreme temperature cycles. This tests how the insulation system will react over time to changes in moisture (humidity) and temperature. The tests and assessment methods outlined in ETAG 004 have been written with an intended working life of 25 years in mind.

The test regime subjects the insulation system to repeated cycles of heat and rain, then heat and cold, and finally heat, rain, freeze and thaw. These cycles are completed in strict order for a set amount of time. During these series of cycles the system can be exposed to temperatures as high as 70°C and as low as -15°C mimicking the extreme weather conditions the insulation system could face during its expected working life. Once complete the test wall is assessed for damage such as surface blisters, flaking, delamination, cracks and other visible changes.

Although mainly aimed at ETICS, other materials such as cement particle boards, glass reinforced plastic (GRP) and MgO boards can also be tested.

The new rig is a significant investment by the BBA and it has been made to address the growth of interest in hygrothermal testing of external wall insulation systems due, in part, to the ability to CE mark this type of insulation system. Although CE marking remains voluntary, for products that do not fall within the scope of a harmonized European Standard (hEN), a manufacturer can obtain CE marking through assessment against the appropriate European Technical Assessment (ETA) and a system of assessment and verification of constancy of performance procedure.

The ETAG 004 hygrothermal test is significantly shorter than other similar tests and coupled with the improved efficiency and versatility of the new rig, cycle times are significantly reduced compared to the test rigs previously used by the BBA. This means a quicker throughput of work increasing the capacity to cope with the anticipated higher level of demand. However, companies are advised to contact the BBA as soon as possible to ensure their products can be scheduled for testing in plenty of time.

To contact the BBA e-mail testing@bba.star.co.uk or telephone 01923 665300.

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Easilift Loading Systems has launched the Advanced Control Centre, an intuitive management system that helps distribution centres and warehouses to efficiently and pro-actively take care of loading bays and vehicle traffic.

The system comprises four easily accessible web-based modules – Service; Dock Management; Facility Management; and Statistics & Reporting – providing a comprehensive overview of loading bay activity.

Benefits of the system include faster maintenance, more effective servicing, reduced waiting times, and improved safety, security and energy savings.

“The modern technology of the Advanced Control Centre integrates a whole host of useful functions into a complete operational solution,” explains Rob Fay, managing director of Easilift. “With unprecedented control over loading bay processes, warehouse co-ordinators can optimise efficiency for maximum uptime.”

The Service module supports everyday operation with 24/7 monitoring of maintenance requirements. An Easilift specialist is automatically notified upon any equipment breakdown, so that problems can be immediately analysed and solved – sometimes before the problem is detected on-site. Where possible, this is achieved remotely, significantly reducing disruption as well as avoiding service engineer call-out charges.

By delivering an ongoing audit of loading bay activity, the Advanced Control Centre can also measure usage to ensure that periodic maintenance is appropriate to the specific bay. Automatic planning arranges routine maintenance at the correct service intervals to extend product lifetime.

Dock Management offers real-time information on the status of all loading and unloading dock stations to enable the swift and appropriate allocation of vehicles. With remote reservations ahead of arrival and automatic re-allocation upon vehicle departure, bottlenecks are minimised and dock usage maintained.

Facility Management complements these capabilities with an ‘at a glance’ inventory of essential station data. With expensive utilities energy lost every time a door is opened unnecessarily, or internal lighting systems left on, warehouse co-ordinators can restrict usage only to active bays. And with security paramount, the system can augment or replace existing walk-around surveillance.

The final module, Statistics & Reporting, gives the customer up-to-date information on everything from loading bay station usage rates to average loading and unloading times. As well as substantiated analysis to optimise the flow of traffic and goods, it delivers an overview of operational costs.

“Effective business management means knowing what is happening in the workplace, in order to reduce wastage and focus on the essentials. With our Advanced Control Centre, distribution centres and warehouses now have an authoritative tool to co-ordinate all loading bay activity,” confirms Rob Fay.

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REHAU will shortly become the first manufacturer to extrude pre-insulated polymer pipework in the UK for use in biomass and district heating applications.

Production of REHAU’s RAUVITHERM pipework will start at REHAU’s factory in Blaenau, North Wales in May and will offer UK based contractors and specifiers a local source of pipe with a lower carbon footprint and improved lead times.

Martin Hitchin, REHAU’s Chief Executive, commented on the move: “We have invested in new manufacturing technology at our largest UK factory in order to meet growing demand from the market for a UK produced pipe.

“It will be produced to exactly the same specification and quality as the RAUVITHERM pipework which we currently supply from our factory in Germany but will have a much lower carbon footprint.”

This is the latest positive indication of REHAU’s commitment to reducing carbon emissions across the entire supply chain and will start to have an impact almost immediately. The carbon savings will be ongoing and are expected to increase significantly as demand for the product continues to surge in the UK.

Steve Richmond, Business Team Leader for REHAU’s Renewable Energy products, added: “In the past year, REHAU has seen sales of RAUVITHERM increase by 100%. This is being driven by the booming UK biomass and district heating markets and, more recently, by the Renewable Heat Incentive scheme launched in November 2011.

“By transferring production to the UK, we will have greater flexibility to meet this growing demand and will be able to offer customers shorter lead times.”

RAUVITHERM is a pre-insulated PE-Xa pipe constructed with layers of cross linked PE insulation and a robust HDPE outer jacket which is longitudinally watertight. It is popular in the UK market because of the high degree of flexibility it offers which simplifies and speeds up installation and because it uses REHAU’s renowned EVERLOC compression sleeve jointing system – proven millions of times in heating and plumbing applications to deliver a permanent leak free joint.

REHAU provides design support for RAUVITHERM installations, assisting specifiers and contractors with pipe sizing, heat loss calculations and drawing up bill of materials from heat network drawings.

RAUVITHERM is part of REHAU’s package of solutions for the district heating market which also includes closed cell RAUTHERMEX pre-insulated pipework, RAUGEO ground source energy solutions and underfloor heating systems.

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Lodge Cottrell use Micronics PF330 Portable clamp-on Flow Meter to substantially reduce commissioning time and fixed installation costs on large scale pollution control plant for coal fired boilers.

Lodge Cottrell is a world-leading supplier of large-scale industrial air pollution control equipment. On a project carried out during 2010 they had a requirement to process the ash extracted from their boiler flue gas treatment system by mixing this with water to form slurry suitable for disposal.

The ash is extracted from the flue gas using an Electrostatic Precipitator with the ash collecting in hoppers, which have varying fill rates determined by the extraction process. These hoppers then feed through to mixers where a specific water flow rate is required to achieve the target slurry consistency from the plant. The plant has 32 water lines with pipe sizes ranging from 18 to 1 inch diameter pipe and the Micronics Portaflo meters were used to accurately measure the water flow rate for the set-up of each mixer section.

The alternative to using the portable meter would have been 32 fixed metering points and as a consequence the use of the portable, clamp-on solution generated substantial benefits in terms of reduced commissioning time – labour and fixed metering point costs, plus the added advantage that the PF330 can be utilised again on other sites with similar requirements.

Having considered various suppliers Lodge Cottrell selected the Micronics – Portaflo PF330 – Time of Flight – portable flow instrument. Portable clamp-on Ultrasonic flow measurement has clear advantages for commissioning/set-up work and Micronics were selected as the supplier due to a combination of their long-term experience with non-invasive, clamp-on technology, product performance and best value.

Project Manager Nigel Dolphin says “The Portaflo PF330 has proved to be a valuable tool for commissioning of the plant water flow lines with considerable time and cost benefits over alternative fixed in-line metering points. The PF330 was simple to set-up/use and the flow measurement performance was good. The product has worked well and the customer service and technical support from Micronics has also been good.”

The potential for re-use by Lodge Cottrell on other plant installations with similar requirements is significant and the project has demonstrated the clear benefits available from using portable, clamp-on, ultrasonic flow metering for temporary flow measurement requirements such as commissioning and set-up of water flow lines. For further information call Micronics on 01628 810456, email sales@micronicsltd.co.uk or visit www.micronicsflowmeters.com. For information about air pollution control systems visit www.lodgecottrell.com.

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As SME manufacturers go global, ERP can help them respond quickly to changes in local market demand, improve business processes and benefit from economies of scale. James Flood of Exact examines why smaller manufacturers must match investment in new plants and sites with investment in enterprise business systems

A growing number of medium-sized manufacturers are benefiting from the opportunities afforded by globalisation. Having been adversely affected by the 2008-9 financial and economic crisis, which saw substantial closures and rationalisations, manufacturing SMEs now have the opportunity to drive a return to pre-crisis employment and output levels in the recovery period.

However, globalisation presents many operational challenges, such as a growing patchwork of IT systems, different cultures and business practices, multiple languages, and complex laws in different jurisdictions, to name but a few. Its also important for those with an international presence to be able to respond quickly and uniformly to changes in local market demand. Whereas service-led firms are able to overcome many of the barriers to international business via electronic means, manufacturers face the considerable task of coordinating the movement of physical goods and resources – whether personnel, raw materials or finished products – between sites, across borders and time zones in a timely manner.

And as they take in new sites, SME manufacturers will have to be just as effective as their larger counterparts in consolidating and exploiting their operations as a single global resource. This ensures their ability to pool capacities to meet orders, rationalise stock and supply across sites, and benefit from economies of scale when bidding for new business and negotiating contracts with suppliers. At the same time, smaller players must operate within the constraints of available budget.

There is general consensus that as the global recession eases, there will be a significant increase in ERP project activity as organisations reactivate postponed technology investment programmes and position themselves to take advantage of the economic upturn. Those getting a firm grasp of international operations, being responsive to changes in international markets and responsive to emerging markets as they crop up will be best placed to benefit from the ongoing process of globalisation.

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• Exact Software

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It’s taken a long time and a lot of hard work but we have done it. PTS have launched what is probably the most comprehensive online Stainless Steel Fastener webshop available. Offering our full range of Metric and Unified threaded fastener in both A2 and A4 material. Customers will be able to log on and use the full customer portal to view activity and retrieve documents, they can even place order and repeat previous orders. Full technical data and specifications are available to view online. Why not take a look www.stainlesssteelfasteners.biz

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Market-leading loading and unloading equipment specialists Thorworld Industries Ltd has achieved the prestigious SAFEcontractor accreditation in recognition of its high standards of health and safety practices.

Under the independent SAFEcontractor scheme, businesses undergo a vetting process which examines their health and safety procedures and track record for safe practice.

Only those companies that meet the very highest standards are accepted into the scheme. Accredited contractors are then included on a database enabling member organisations to vet potential contractors before they even set foot on-site. What’s more, these users agree that they will only engage those contractors who have received accreditation.

The SAFEcontractor scheme has been running since 1999 and a wealth of well-known names have signed up to use the scheme to vet contractors, including Nestle, Kellogg, Debenhams and Virgin to name but a few. Thorworld managing director John Meale said: “Health and safety is vitally important to us, in everything we do – it’s a fundamental keystone of our business from initial product design and development through to manufacturing and installation.

“SAFEcontractor accreditation allows us to further demonstrate our positive commitment to health and safety, confirming to prospective customers that we have all the right systems and procedures firmly in place.”

Thorworld is firmly established as one of the foremost designers, manufacturers and suppliers to the loading bay and materials handling sectors and is recognised as both a market leader and innovator in the supply of quality engineered equipment.

BSI registered with ISO 9002 accreditation since 1992, it was one of the first companies in the industry to achieve the latest international quality management ISO 9001 (2008) standard, and now has an extensive list of prestige customers across a wide range of industries and business types, including distribution, logistics, transport, retail, food, drink, manufacturing, industry, waste management and recycling and the service sector.

Thorworld provides a one-stop, single source for the UK’s widest range of high quality loading bay and materials handling equipment, safety aids and accessories, including dock seals and shelters, dock levellers, modular loading docks, dock plates and boards, dock and vehicle bumpers, wheel chocks, vehicle restraints, traffic lights, dock lights, wheel guides and alignment curbs, access ramps, trailer safety jacks and mobile yardramps – (yardramps are available for purchase or rental on a sale or return basis through the company’s RentARamp division) – together with the Truckloada mobile yardlift and the Dockloada scissor lift platform.

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Tesco DCs

An innovative hi-tech management reporting and safety system designed to prevent the premature departure of vehicles from the loading bay is set to be installed at the Goods In section of every one of Tesco’s distribution centres across the UK.

The supermarket is investing in the Dock Management System, which was jointly developed by UK firms Easilift Loading Systems and Traka, after it impressed during a pilot scheme at Tesco’s distribution centre in Hinckley, Leicestershire.

The system combines Easilift's dock door and associated control equipment with Traka's electronic key control system and was tailored to complement Tesco's existing safety processes, creating a high-tech solution to the problem of vehicle drive-off accidents.

The Dock Management System works by using electronic keys – known as iFobs –each containing a unique electronic chip, which is individually programmed to open or close one specific door when inserted into a control panel.

At Hinckley, the system is now an integral part of a robust protocol whereby drivers are required to hand in their ignition keys when they arrive at the Goods In office. The keys are clipped to an iFob, which is inserted into the main Traka control panel, allowing a corresponding iFob to be removed and handed to the driver.

Only then is it possible to open the bay door, when an authorised operative inserts their personal iFob into a secondary control panel located adjacent to each door.

Once loading or unloading is complete, the operative closes the door. This sends a message to the Goods In control box, permitting the removal of the driver’s keys – but only after the deposit iFob is inserted back into the box.

Tesco trialled the Dock Management System at 26 Goods In loading bays at the Hinckley depot. The bays are used by between 300 and 400 vehicles each day, many of which arrive from overseas, representing a stern test for the new Easilift system.

“We have an excellent safety record at Hinckley, but worker safety is paramount and there is always room for improvement,” said Joe Carthy, distribution health and safety manager for Tesco UK and Ireland.

“It was important therefore that the system was tested in the Goods In section, where we deal with a high volume of drivers, many of whom will be unfamiliar with the layout.

“If the system worked there, we knew that it would be able to achieve our objectives at other loading bays too.”

Fitting the system involved surface-mounting cabling on the inside of the exterior walls and linking 26 individual boxes stationed next to each loading bay door with the control panel in the Goods In office.

“The Easilift Dock Management System was attractive to us because by using control boxes and indicator lights, it lessens the chance of human error,” said Joe.

“This was a limited trial, but the results were fantastic. The system was easy to operate and to understand, and it took a huge amount of human element out of the process. Importantly, it made people feel safe and put them at ease.”

Although the system was developed with a health and safety angle in mind, it has a whole range of other benefits. The system minimises the amount of time the door is open – which can save money and reduce carbon footprints for chilled distribution centres – and, furthermore, can provide an audit trail, logging who used what door and for how long.

This can not only improve efficiency and assist companies in tracking down any missing stock, but can also help with servicing costs. By using the information recorded within the system and the reports generated, a company can devise a servicing programme which takes into account how much the door is used over a set period of time.

The Dock Management System can be easily retro-fitted to virtually any loading bay door and will now be installed in all of Tesco's distribution centres, representing what David Whyatt, sales director at Easilift Loading Systems, described as an excellent way to launch the product onto the market.

He added: “We are thrilled that Tesco has agreed to roll out the Dock Management System UK-wide and by doing so has shown great foresight by investing in a solution which has the potential to cut out serious accidents.

“There could have been no tougher test for the system than to trial it at Hinckley, which is an extremely busy depot where any shortcomings in the system would have been very quickly highlighted.

“It is testament to the technology and expertise at Easilift Loading Systems and Traka that the system proved itself to be watertight and demonstrated that it goes further than any other system on the market to offer peace of mind.”

With 35 years’ experience in the design, manufacture, installation and maintenance of high quality loading bay equipment and industrial doors, Easilift Loading Systems is the UK’s leading specialist supplier of total loading bay solutions to some of the biggest names in retailing, manufacturing, logistics, distribution, warehousing, building, construction and the service sector.

In addition to its unique new Dock Management – Anti Drive-Off System, the company provides a complete range of loading bay equipment, including dock levellers, dock shelters & seals, industrial & high speed doors, and lifting platforms, together with a wide selection of safety aids & accessories such as dock plates, dock bumpers, dock & traffic lights, wheel guides & vehicle restraints, and integrated control systems. Easilift also provides comprehensive service and maintenance programmes for all makes and types of loading bay equipment – irrespective of the manufacturer.

Easilift was also one of the pioneers in the design and installation of dock pod systems, which are complete stand-alone loading bay enclosures that can be installed directly onto the external face of a building. Suitable for new buildings, extensions and refurbishments, they can be quickly and easily re-positioned, if required, and are ideal for use with the increasingly popular and highly cost-effective double deck trailer units.

As the UK’s leading loading bay specialist, Easilift was one of the first in its sector to achieve the prestigious SAFEcontractor accreditation in recognition of its excellent health & safety record and competence, confirming to prospective customers that effective policies and systems are in place.

Easilift is a member of the Loading Systems International Group, one of Europe’s foremost manufacturers of loading bay equipment. The Group has over 450 employees across Europe and a total turnover in excess of 60 million Euros.

An active member of the Association of Loading & Elevating Equipment Manufacturers (ALEM) and the Confederation of Construction Specialists, Easilift operates to the International ISO 9001:2008 Quality Management Standard. The company has Investors In People Bronze status accreditation and is a participant in the Construction Skills Certification Scheme (CSCS), with all its engineers fully qualified under the CITB Site Supervisory Training Scheme.

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ELGA Process Water is helping Veolia Environmental Services
maximise boiler efficiency at a major energy recovery facility

When Veolia Environmental Services required a specialist conditioning chemical supplier for the boiler water at its Tyseley Energy Recovery Facility it turned to ELGA Process Water for help. The Tyseley plant incinerates 350,000 tonnes of Birmingham’s non-recyclable rubbish each year and exports 25MW of electricity to the National Grid, suitable to power over 41,000 homes. The facility has two 45bar 400°C water tube boilers delivering 67 tonnes per hour of steam to the high pressure turbines. It also has a 10bar waste heat shell boiler fuelled by a clinical waste incinerator, and this supplies steam to a low pressure turbine.

In order to maximise boiler efficiency, the quality of the water fed to the boilers has to be carefully controlled. Tyseley produces high purity deionised water on site and adds chemicals to scavenge oxygen and adjust the pH to prevent corrosion. The combination of two types of boiler with common feed water and condensate systems means that controlling the boiler water chemistry at Tyseley requires a specialist solution.

ELGA Process Water, a Veolia Water Solutions & Technologies company, carried out a detailed site survey with technical support from their Boiler Competence Centre. A solution was developed, which included the appropriate chemicals from their Hydrex range to provide protection of the boilers, turbines and condensate system, as well as recommendations for regular service support to maintain ongoing boiler efficiency and optimal performance.

Andy Bullock, Operations Manager for the Tyseley facility is pleased with the result: “ELGA Process Water worked closely with us to achieve the appropriate boiler water quality and we’ve been particularly impressed with the technical support from the Boiler team and their readiness to formulate bespoke conditioning chemicals for our system.”

About the company:

ELGA Process Water is part of Veolia Water Solutions & Technologies (VWS), a subsidiary of Veolia Water. VWS is a leading design & build company and a specialised provider of technological solutions in water treatment. With over 9,500 employees in 57 countries, Veolia Water Solutions & Technologies recorded revenue of ?2.5 billion Euros in 2009.

Veolia Water, the water division of Veolia Environnement, is the world leader in water and wastewater services. Specialized in outsourcing services for municipal authorities, as well as industrial and service companies, Veolia Water provides water service to 95 million people and wastewater service to 66 million. With 95,789 employees in 66 countries, its 2009 revenue amounted to ?12.5 billion.

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Precision Technology Supplies Ltd have consistently increased the range and depth of stock it hold for Metric Stainless Steel Fasteners. With the range starting at M1 and covering up to M24 we now offer more than ever before. Also big increase in the depth of stock in our Unified(American) Threaded Fastener range starting from 0un and up to 1” diameter in stock. For full details visit our website www.pts-uk.com

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