Maintaining the trajectory for innovation and growth

20 February, 2023

The fluid power industry and related technology sectors have certainly has to face their fair share of challenges over the past couple of years or so. One is undeniably issues surrounding energy. Ariel Rubinstein, general manager, Atlas Copco Compressors UK & Ireland, comments that the demand for energy efficient products is increasing as manufacturers seek to play their part in a low-carbon economy. “This means that products which add real value for end users in terms of reducing both their energy consumed and their CO2 emissions are more in demand,” he says. “We have noticed that the green credentials of the compressor supplier have become more and more important to compressed air users over the course of this year. We are no longer just talking with customers about how much electricity they can save through purchasing an energy-efficient air compressor, but also about the carbon footprint of the compressor over its lifetime and by how many kilograms per year the user’s CO2 emissions can be reduced as a result of using an energyefficient compressor.”

Rubinstein says Atlas Copco Compressors is also continuing to discuss increased compressor connectivity with its customers. “There are now more than 5700 Atlas Copco compressors which are connected in the UK via Smartlink,” he says. “This figure was 3000 when we contributed to the Hydraulics & Pneumatics Boardroom Report in 2021, so, it has more or less doubled in two years. Smartlink provides an enormous amount of intelligence data on how our compressors are running – air demand, the ambient conditions, the required air quality, whether the system has leaks etc. This stream of valuable information is gathered and processed and can be used to optimise the performance of the equipment, increasing the customer’s efficiency and preventing potential technical problems.”

Skills shortage

Vanda Jones, executive director, the British Compressed Air Society (BCAS), reflects that many BCAS member companies have faced some challenges over the past 12 months. “Manufacturer member companies have faced similar hurdles to many other capital equipment markets, including supply chain disruption and the rising costs of both the energy and components used in the manufacture of compressors, dryers and related equipment,” she says. “Our distribution members too are facing increased business costs and skills shortages, and yet all our members continue to deliver continuity of service with many companies growing during these challenging times.”

Martin Cuthbert, managing director, Webtec Products Ltd, believes we have seen many positives this year, and maintains that one was driven by Brexit. “Webtec Europe was formed as a result and has been a great success,” he points out. “We now have a full sales and service customer support centre in Germany. This was completed in October 2022 when we commissioned and completed the repair centre with around £250,000 of investment in terms of machinery tooling and training. The huge benefit to the business is that we can now service customers in Europe direct and any products don’t have to be shipped back to the UK, so we sell in Germany and servicing and repairs come back to Germany.”

Cuthbert adds that the Ukraine situation, material costs and inflation have been challenging. Moreover, although Webtec focused on forward buying to buffer issues as well as looking at engineering alternative parts, it still experienced some issues. “Our lead times increased to 16 weeks at the end of 2021 because of supply chain issues, but today we are back to pre-COVID lead times of six weeks,” explains Cuthbert. “So, from that point of view the Webtec team has done a great job in mitigating and building supply chain relationships. We have reviewed where our raw material suppliers are located geographically.

“We already source over 80% from UK and near Europe, however we are always looking to improve. For example, in the past we may have sourced a die cast box from China but now we look to the UK for the tooling and die cast. This makes more sense for a couple of reasons. We have greater control over the supply chain. After all, how do you explain to your customer that you can’t deliver because the lower price material has been delayed on a boat for three months? Also, it helps reduce our scope 3 emissions, which is part of our goal as we head towards net zero.”

Supply chain challenges

Steve Sands, head of product management & marketing, Festo, considers that change has been the only reliable constant in 2022. “The supply chain challenges, particularly around semi-conductor chips, has plagued virtually all automation manufacturers,” he says. “We all require many different chip devices to be assembled into a whole host of intelligent devices from sensors to controllers and communication devices. Supplies have consistently been late or only partially delivered and the costs have rocketed. Purchasing have worked tirelessly trying to globally procure the parts needed; and in the more severe cases, significant development engineering time has been invested to redesign existing PCBs.

“A good example of this is Festo updating our servo drives to reduce the number of variants from 21 to 6 by using a multi-protocol approach which increases availability. There are some signs of stabilisation and even increased delivery reliability: however, in many cases quantities are still restricted and are disrupting production. It will take the whole industry well into 2023 to recover to the point of ample, smooth and predictable supplies.”

Sands believes the invasion of Ukraine further exacerbated the supply situation, globally jittering energy prices and frightening a lot of the European population and industry dependant on Russian energy supplies. “These shockwaves have created an ever-greater need for agility and resilience,” he maintains. “Festo already had plans underway which have mitigated some of these affects, e.g. our extensive plans to reduce energy consumption in line with our sustainability objective of carbon neutral production and main offices by the end of 2023.”

Price volatility

Klaus Loeffler, marketing executive, Jubilee Clips, makes the point that during 2022 the high level of volatility within the metals marketplace was a major issue. “As a company whose products are reliant on the supply of metals, it was difficult for us to know precisely how to react to the fluctuations in prices when they were sometimes doubling or even tripling overnight,” he says. “However, most of our customers understood the situation and knew that we needed to reflect this situation in how we priced our products.

“Fortunately, prices have since levelled off to a large extent, so we can now forecast and estimate costs rising with inflation more accurately. Of course, prices might go up again in the near future, but I don’t think we will have to endure the same type of highly volatile situation that we did during February and March last year.”

Loeffler adds that because of COVID, lead times for delivery of metals and other materials were extended during 2020 and 2021. “Because of this, customers were stocking a lot of products in order for them to be able to supply goods to their end-users within a short timeframe,” he says. “Now, fortunately, the lead times have returned to a more reasonable level, so customers are destocking to a large extent, which is good in terms of our company being able to get back to supplying more regular orders.”

In terms of specific sectors, Loeffler explains that a large part of Jubilee Clips’ customer base was automotive, but this has now changed mainly to the automotive aftermarket. “This is because only high-performance cars tend still to have the requirement for hose clips,” he says. “The rest tend to rely on quick-fit, cheaper materials involving spring clips or glued parts. If, on the other hand, vehicles in the aftermarket need replacement parts, garages understandably want to source standard traditional hose clips. So, that remains a strong sector for us. Also, new technologies related to renewable energy sources are turning into a growing market segment for Jubilee Clips.”

Market share

Neil Anderton, hydraulics & industrial director, Slack & Parr, explains that the company manufactures all its solutions in-house at its Derbyshire factory and, as a result, its supply chain is relatively short. “So, while some materials – for example 316 stainless steel for our corrosion resistant products – have been slightly slower to arrive, we haven’t experienced the negative impact of global geopolitical issues on the way we do business,” he explains. “In fact, in the past 12 months we’ve expanded our share of the UK market because we’ve been able to fulfil orders more quickly than some of our overseas competitors.”

Colin Mander, strategic business line director and Northern Europe compressor lead, Ingersoll Rand, considers there is no question that the current energy crisis has brought the cost and efficiency of compressed air systems into sharp focus for all Ingersoll Rand customers. “At our recent distributor conference, the energy consumption (and the associated cost) of compressed air energy was the most talked about issue and we discussed the numerous ways that compressor sales and services teams can help mitigate for these risks,” he says.

Mander explains that, in particular, Ingersoll Rand continues to support the BCAS 10% Taskforce campaign and is encouraging customers to look at all the cost-efficient and simple ways to reduce their compressed air system energy consumption. “Whether it’s implementing heat recovery systems, investing in variable speed technologies or investing in energy efficient downstream equipment, there are numerous ways to improve energy consumption, often with rapid payback on investment,” he says. “For many years, the industry has used a formula to calculate compressed air cost of ownership, comprising capital investment and installation at 10%, maintenance at approximately 8% and energy costs making up the largest proportion at 82%. Now, with the global rise in electricity prices, the energy costs of compressed air have increased to as much as 91% of the total cost of ownership, meaning that customers need to re-evaluate the way that they assess their compressed air energy costs.

“Total running costs over the last ten years for a 160-kW compressor have more than doubled. Put simply, for every £100,000 spent on compressed air previously, around £82,000 of this was the energy costs. Now, this figure has risen to £91,000 – with energy costs doubling in the past two years alone. The good news is there are numerous high performing, energy-efficient compressors available on the market, which can help reduce a site’s reliance on electricity considerably.”

Stephen Wright, managing director, Thorite, reflects that everything over the past year has been caught up with endless rounds of price increases and supply chain issues. “What are the causes? One would respond ‘all of the above’,” he says. “Whilst there are still impacts from Brexit, most of the issues are built around the supply difficulties associated with coming out of COVID, especially anything involving China, and the effect of the Ukraine war. It’s a bit like a leaky bucket – you fix one leak, and another leak starts. Lead times have gone up dramatically and we are being quoted six, nine and even 12 months on some products. It feels like we’re going back to the dark ages of the 60s and 70s! I think the whole sector is focused on fixing this, but the target continues to move.”

Semiconductor shortage

From the perspective of Steve Schofield, director and chief executive, British Pump Manufacturers’ Association (BPMA), there are many challenges in play today, from skill shortages to the ever-increasing price of energy. “However, the COVID pandemic broke down long-standing supply chains and has caused huge shortages of various materials and components used in the manufacture of pumps and their related equipment,” he says. “This is particularly evident in the global shortage of semiconductor chips, which are frequently used nowadays in the electrical components that control pumps. Prices have risen across all sectors and after many years of stagnant or reducing price levels we are finding many of our members are having to increase prices. In some cases, we’ve even witnessed several price-rises within a 12-month period, due to the ongoing increase in component parts.”

Schofield adds that importing and exporting has proven a challenge for many BPMA members with increased costs and bureaucracy. “On the horizon is the change from CE Marking to UKCA Marking, but eventually we see the UK Government diverging all regulation relating to our industry in order to have their own set of UK-centric safety and technical regulations,” he says. “If this does happen, pumps that are sold to the UK market will need to meet different regulation, testing and safety standards to those of the European market. Quite simply, this will add another level of business complexity to an already heavily regulated sector, the benefits or which are hard to fathom.”

One of the ongoing issues in Brussels concerns water pumps. “This is legislation that we’ve been pushing for many years,” says Schofield. “The Consultation Forum on water pumps was back in 2019 but because of COVID the outcome has been delayed. However, potentially we could be looking at saving 35 to 40 TW of electricity by introducing this. We’ve been part of it for such a long time and we want the UK to do what Europe is doing.”

As Schofield explains, BPMA members supply pumps for all sectors that require the movement of liquids from A to B, which means that something that is a trend in one sector might not be in another. “However, one trend, or rather issue, that we are dealing with in the domestic sector, and which has been accentuated by the global shortage of semiconductors, is the supply of noncompliant circulator pumps,” he points out. “Manufacturers across Europe are struggling to hit their usual production quotas, with lead times becoming increasingly longer, and, as a result, wholesalers are turning to cheap noncompliant circulators supplied from the far east to meet the market demands. The BPMA is working hard to try and stop this through its relationship with the Market Surveillance authorities.”

Changing requirements

Have end users’ or OEMs’ requirements for systems and equipment changed over the past year or two? Chris Butcher, managing director, the British Fluid Power Association (BFPA), considers that from a technology aspect, requirements haven’t changed a great deal over that timeframe. However, he believes a focus on carbon footprint and energy reduction, the increase in hydrogen application and a further integration of electronics, mechatronics and robotics will drive the years ahead.

With regard to air compressors, Jones makes the point that the energy consumption of a compressed air system has always been an area where operators have been looking to make savings. “But now, with the current energy crisis and escalating cost of ownership, companies are looking for more ways to save energy – outside of new capital equipment investment alone,” she says.

As part of its new 10% Taskforce campaign (www.taskforce10.bcas.org.uk), BCAS used figures from the recent UK Energy-related products policy study, conducted by ICF in May 2021. It calculated the combined energy usage for the mid-point of all industrial compressor technologies over their lifetime at 11.71 TWh. When the report was first prepared, the UK average non-domestic electrical unit cost was £0.1249/kWh, which equated to £1.475 billion being spent by UK companies to generate the compressed air their businesses rely on 

“Now, of course, wholesale gas prices have risen at an unprecedented rate and savings will be considerably higher,” says Jones. “Businesses are advised to refer to their electricity unit charge to calculate the potential savings. Add to this the fact that over 30% of this energy is being wasted through inefficient practices and there is much that businesses can do to cut this figure significantly.”

Yet, states Jones, compressed air energy consumption is often overlooked, when the potential for wastage is substantial and represents a considerable overhead, not to mention carbon footprint that could be reduced. “Users are therefore being encouraged to look at alternative ways to minimise their energy consumption from compressed air – whether it’s reducing air leaks, ensuring better housekeeping practices, improving maintenance, and managing air downstream to name a few,” she says.

Where energy surveys have been completed in the past, Jones believes now is an excellent time to revisit the outcomes and their business benefits. “The increase in energy costs has, in many cases, meant that the payback for these investments has been reduced substantially. Anecdotally we have many of our members reporting a reduction from years to months.”

Health and safety

Are current mandatory or established health and safety practices adequate in our industry? Wright believes the simple answer is yes. “Within the supply industry there is a good understanding of the current regulations and codes of best practice,” he says. “It is still questionable whether end users are always aware of regulations, typically around PSSR and condensate recovery. It is primarily down to end users to understand their responsibilities, but suppliers and distributors need to ensure that end users understand all their implications.”

Butcher believes health and safety practices can always be improved. “The BFPA works closely with its members to ensure they are up to date with the latest standards related to health and safety,” he explains. “On some subjects, we offer training to ensure people understand the risks associated with working with air and fluids at pressure. More recently, the Association has formed a partnership with the BSSH (British Society for Surgery of the Hand) in promoting the dangers associated with a fluid injection injury, The partnership resulted in the BFPA giving a presentation at a conference in London attended by some 5000 hand surgeons from around the world.

Rubinstein stresses that Atlas Copco Group has ambitious standards for workplace safety. “We commit to eliminating hazards and reducing occupational health and safety risks in all of our operations,” he says. “There is something that I think is worth repeating to compressed air users, as there are some who may not realise this: remember that it is a legal requirement to have a Written Scheme of Examination (WSE) in place on any pressure system operating at 250 bar litres or above, in accordance with the Pressure Systems Safety Regulations. For example, a compressor with an 11 bar max working pressure with a 50 litre air receiver = a 550 bar litre compressed air system and is there likely to need a WSE.”

Jones reflects that as we settle into our new legislative frameworks post Brexit, trade associations are working together to ensure that common messages are not only delivered to the corridors of political power, but also that they provide a resource for government when it looks to make legislative changes. “Many of these legislative reviews have yet to crystalise into legislative change but, none the less, trade associations such as BCAS and lobby groups have been very active on the industry’s behalf,” says Jones. “The recent ‘UK Product Safety Review’ consultation is a case in point. We are used to working with the legacy legislation but must now work with government as it looks at the long-term approach to product safety and how to ensure that the regulatory framework is fit for the future.”

Jones adds that along with the UK ErP (Energy-related Products) Policy Framework proposal, this demonstrates the drive to review legacy legislation and she believes it is critical that all stakeholders are represented in this process. “This is where relationships between trade associations and government departments are critical, so that we can consolidate the voices of many into clearly communicated positions, ensuring that industry is represented,” she says.

Training

Do currently available training courses meet companies’ requirements? Loeffler explains that Jubilee Clips is always keen to recruit enthusiastic young people on to its apprenticeship program to secure ongoing excellence in toolmaking, maintenance and manufacturing. Additionally, he points out that the company has recruited young people to train as operatives in the warehouse, learning skills such as forklift truck driving or general packing, dispatch and warehouse management.

Anderton explains that Slack & Parr’s long-established apprenticeship and training schemes are fundamental to the structure and success of the company’s business. “We’ve developed a programme that is internationally recognised and produces highly skilled engineers in all disciplines, from mechanical engineering to machine operating,” he says. “In the past few years, the move from apprenticeship frameworks to Engineering Standards means we’re now forced to choose a fixed route for each apprentice at the start of their training.”

Anderton adds that, previously, Slack & Parr’s apprentices have had the opportunity to experience everything an engineering business such as Slack & Parr has to offer. This included the possibility of moving between disciplines with close supervision. “This meant we could provide tailored programmes of learning that nurtured each apprentice’s skills and supported their ambitions really well, allowing them the possibility of changing path as their understanding of engineering grew,” explains Anderton. “We found this was a particularly effective way of producing exceptionally well-rounded, experienced young engineers who knew what route they wanted their careers to take. Although we’re still focused on providing the very best experiences and training for our apprentices, the move to a more rigid and prescriptive model of training laid out in the new Engineering Standards approach to apprenticeships feels more restrictive and less intuitive.”

Butcher points out that many BFPA members offer training in flexible hose technology through their own business in partnership with the BFPA. This training has now become a recognised industry standard in both the UK and Overseas. The Association, together with its members, also provide fluid power training to a very high standard, although this standard is typically not recognised. “We have implemented training courses to the new BFPA standard – an initiative that has been driven by our members who told us what they saw as the most important requirements for training,” says Butcher. “The biggest challenge we face in the fluid power sector is that whilst apprenticeships might include modules associated with fluid power, the standard of training is currently dictated by the level of knowledge of the person delivering the course, the technical information available to them and any test rig capabilities the training/education establishment has onsite. Having educational centres that recognise the BFPA standard will be key in having a foundation or introduction to fluid power, and then building further training in line with the BFPA courses. A gas engineer has a Gas Safe Register certificate, and our goal is to have a BFPA-recognised standard. Until we get to this point, it will be an ongoing challenge to meet the industry requirements.”

Rubinstein states that BCAS continues to provide specialised courses and advice on compressed air systems. “Within Atlas Copco, we also offer a wide range of online and physical training to our own employees and distributors,” he explains. “In addition, we have created a compressed air wiki, dedicated to explaining everything there is to know about compressed air, compressors, air treatment and more. This is an excellent free resource for end users and students alike, and we invite readers to send in their questions so that we can expand the wiki if there is anything missing.”

Jones says BCAS is the only UK trade association with responsibility for the compressed air and vacuum industry and its business sectors. “We recognised that there had been no dedicated apprenticeship available for the future development of engineering technicians into our industry and set about addressing this skills gap,” she points out. “A Trailblazer group was formed and working with our members and the IfATE, we launched our Compressed Air and Vacuum Technician (CAVT) apprenticeship scheme in 2021. Following the selection of our end-point assessor organisation (EAL, part of the Enginuity group), candidates began enrolling on the course from early September 2021, working with Semester Learning and Development (Semester), also the first provider in the UK to run the scheme. During the three-year apprenticeship, candidates will learn how to commission compressed air and/or vacuum equipment and their associated systems, alongside service and maintenance, fault diagnosis, repair and system optimisation. The course will also include the development of transferrable skills, which can be provided via BCAS training courses including working safely with compressed air and compressed air treatment technology to name a few. The final two years will be more focused on developing the key engineering skills required by the industry, including installation, commissioning, service and repair of compressed air and vacuum systems.”

Schofield believes the BPMA was fortunate to have first got involved in training back in the 1990s. “Over the years, we’ve adapted and increased our training offerings, and we also have our own training officer,” he says. “Out of the income we receive from the membership a considerable portion comes from training. Our training is all knowledgebased, is something for the members and has been put together by the members. It covers everything from the fundamentals through to what is probably one of the hardest e-learning courses there is globally available on pumps. This is backed by the National Open College Network in the UK. We also offer certified pump system auditor training. We have a relationship with the Department of Energy in the US with the backing of what is now BEIS in the UK. We secured funding and we still push that and will continue to push that. This training relates to the carrying out of audits on pumping systems in the installed base.”

Schofield explains that the BPMA doesn’t get directly involved in apprenticeships. “If you came into the pump industry and you wanted to be a pump fitter, for example, you would still take a mechanical engineering-based apprenticeship and learn about pumps externally. Our members then put their apprentices on our courses. We’ve looked at working with universities over the years but we’re not an NHS and only employ about 12,000 people in the UK. So, the pump industry isn’t really big enough for universities to take it on. However, it’s certainly something we’re developing. At the moment, our technical officer is in the process of finishing a variable speed drive course and last year we finished compiling a two-day maintenance and repair course – and there are more initiatives like that.”

Investment

Sands has seen significant investments being made by universities and colleges into facilities that can take trainees from the base engineering technologies up to advanced production lines incorporating many facets of digitalisation. He explains that these include technologies such as digital twins, robotics and artificial intelligence. “Whilst these are great investments, it is also clear that many establishments are struggling to recruit and retain skilled engineers and trainers for these technologies as they are also in high demand from industry,” he says.

Sands believes face-to-face training courses are still catching up with demand following the COVID lockdown restrictions. “In parallel, the time feels precisely right for blended training, combining online modules with hands-on workshops,” he says. “Festo launched an online training portal a couple of years ago. Since then, the site has been populated with 100s of modules, from individual training nuggets to complete learning paths. Training plans can be prepopulated, or individuals can pick their own development areas with topic areas reinforced with shorter, hands-on workshops led by an experienced trainer to answer questions and guide the small groups. This definitely feels like the way ahead and will be supplemented with Virtual Reality supported modules in the future.”

Mander points out that Ingersoll Rand has a comprehensive programme of training courses, delivered by experts from within the business for its own sales and service teams and distribution network. “It’s fair to say that COVID affected the delivery of some of these programmes, although we switched to online learning, which proved successful,” he says. “However, it is good to be back with faceto-face delivery of our product and service training with the teams.”

Wright reflects that whilst work has been done by BCAS to provide an apprenticeship for service engineers and there are plenty of engineering apprenticeships out there, the main thread for education is still down the academic path. “More needs to be done to encourage parents and students to take up courses that lead into the manufacturing sector,” he says. “A few years ago, University Technical Colleges (UTCs) seemed to be the coming thing, but their fashion seems to have waned. Equally, T Levels still seem to be the mystery they were on the first day they were mooted.”

Cuthbert reflects that we all still recognise the skills shortage in the industry and how difficult it is to fill vacancies including apprenticeships. “Many training initiatives are being driven by industry such as the nationwide Make UK’s ‘National Manufacturing Day’,” he says. “Webtec took part in this initiative, and we also actively support the Arkwright Scholarships, Primary Engineer Leaders Award. However, we still need more schools, colleges and universities to get on board to encourage students to consider engineering as a career, promote apprenticeships and the future opportunities that this will bring.”

Digital transformation

Are digitally transformative methodologies gaining traction within the UK marketplace? Butcher believes they are because the fluid power industry is the hidden force in manufacturing. “The integration of electronics is well established, however, and this will continue,” he says, adding that mechatronics and robotics are also becoming much more integrated into the fluid power industry. “Energy efficient systems will always drive technology as well as the ROI, and overall machine performance will drive a greater level of integration,” says Butcher.

Whether it comes to the use of time, energy, materials or processes, Rubinstein believes the smart factory of the future will be much more efficient than it is today. “A large part of the efficiency will come from automation,” he says. “All types of different machines from different manufacturers will be able to ‘communicate’ with each other. And, using central control and artificial intelligence, they will know what to do based on that information. For example, the compressed air system, as a connected part of the smart factory of the future, will be aware of any increase or decrease in production demand and will adapt its performance accordingly, without a human being involved.”

Wright considers that digital transformation is a slow burn, but his gut feel is that more and more of what Thorite sells is less focused on purely mechanical solutions and is more electropneumatic or has some form of advanced monitoring in it.

Jones points out that with the advent of smart technology, equipment performance monitoring is now an active part of many BCAS’s members’ service routines. “The monitoring systems are sophisticated enough to not only advise on when maintenance is due, but also to look at the usage of a compressor,” she explains. “For example, when these systems are operational, it is possible to measure the running time of a compressor vs the load time. At a recent member visit we were able to evidence that its compressors were running continuously, 24 hours a day, but with only 15% load. This presents another opportunity for the end user to work with its supplier to ensure that the equipment is not only functioning correctly, but that it is being used in the most efficient way.

“With the current unprecedented cost of energy, this is yet another important benefit of system monitoring and of course, we are all aware that planned maintenance is far more efficient and less expensive that an unplanned outage. Speaking to equipment suppliers will enable customers to understand what features are available from their current compressor units and also what can be retrofitted.”

Loeffler points out that Jubilee Clips continues to automate much of its production machinery so that the high quality of its products is standardised. “If a part is screwed together by a machine in an automated fashion and if the process is more controllable digitally, then the standardisation of quality and consistency is going to be better than if something is done semiautomatically,” he says. “Because of this, our machines are now largely computer-controlled using more sensor technology.”

Monitoring

Cuthbert reiterates that preventative and predictive maintenance has become increasingly important to customers. “To meet this demand, we introduced the CTA flow monitor, which focuses on cost of ownership, and you can draw parallels with other industries such as the automotive market. A few years ago, buying or leasing were the only options, now people are looking at subscribing to cars, just use it, service it, but not own it. Companies in the machine industry are also not only looking for the lowest possible cost to purchase but are looking at how much it will cost to run the machine, including maintenance and down time.

“This links into people looking at more telematics and the idea that we shouldn’t just be measuring temperature and pressure but also the flow – as it is the flow makes it go - as they say in hydraulics. If you are not measuring that then you are making assumptions about it and that can be dangerous as they can be completely wrong so something like the CTA, that has been designed for heavy industry, but still has excellent repeatability and ruggedness, is part of the jigsaw puzzle to enable machine manufacturers and operators to improve productivity and upside by predicting that something will fail before it does by having additional information about how that machine works.”

Sands believes UK training institutions are catching up with the investments that were seen on the continent in the preCOVID period and there are more digitalisation pilot installations in operation. “We are nearing the planned mid-point for the formal digitalisation program laid out in the Industry 4.0 plan in 2010/11,” he says. “Awareness of the opportunity has certainly risen and in some cases people are disappointed at the lack of progress toward the utopian vision. However, solid progress is being made. Digital twins are one of the foundations of digitalisation and are planned to be used throughout the machinery lifecycle from design to operation and even repurposing, or recycling. At the recent SPS Drives fair in Nuremburg, Cadenas announced their commitment to supporting the roll-out of digital twin technology in the form of the Asset Administration Shell [AAS] alongside the likes of Festo, BoschRexroth, Harting, Phoenix Contact, Sick, Siemens and Wago. This is a clear reflection that digitalisation cannot take place in isolation but is an industry-wide trend that needs to progress in concert.”

Mander comments that Ingersoll Rand customers are looking increasingly to introduce smart technologies and analytics to their compressed air system, using products such as iConn smart compressor service, which provides comprehensive service data in real time. He adds that the Internet of Things and data analytics can help operators to understand how efficiently a compressor is running, and whether any improvements can be made.

“These insights will not only help highlight any potential issues now, but also enable operators to forecast any potential future problems, based on deteriorating machine performance,” says Mander. “We are certainly seeing more customers invest in predictive maintenance models based on real-time data to help reduce energy consumption, improve process efficiencies and limit any risks. Connectivity continues to be a key focus in the CompAir portfolio, with the company’s iConn service offering intelligent insights that help operators monitor a system’s performance in both real-time and remotely. Accessible from smartphones and tablets, the browserbased system ensures users can proactively manage any potential issues that arise at all times, reducing associated downtime and guaranteeing the system is performing as required.”

Reshoring

What is the current status regarding reshoring? To add some context, Butcher makes the point that many OEM suppliers were forced east by their customers to drive down cost. “This may have been a great opportunity in the early 2000s, however, due to strengthening currency in countries such as China, rapid wage rises and volatile fuel and commodity pricing, companies have been reshoring in recent years,” he says. “This will clearly not result in the moving of all demand back to the UK, but much of it will be closer to home. Lead times along with working capital costs will certainly reduce. Driving reshoring to the UK, however, needs to be incentivised or assisted. Because of bureaucracy and some bewildering political decisions since Brexit, this has not helped the situation. I think UKCA is a perfect example of unnecessary red tape and cost.”

Butcher adds that the UK is overflowing with technical and engineering excellence together with an abundance of talent. “The manufacturing industry in the UK employs over 2.5 million people and generated £183 billion in revenue in 2022,” he explains. “That positioned us as the ninth largest manufacturing nation in the world. Onshoring still needs to be cost competitive, and this must be a focus of government. Government should also support the effort to educate and train people to fill such jobs. The UK is still respected globally as a technology and manufacturing nation.”

Jones believes that, in a world of constantly changing legislation and standards, it pays to work with a supplier that can offer the right levels of support, backed by engineering and technical expertise. “As the only UK technical trade association open to manufacturers, distributors and end users of compressors, vacuum pumps, pneumatic tools and allied products, it is an approach we have always advocated – helping to connect our members with industry end-users to help specify, install, maintain and service their equipment,” she says. “Therefore, to help further strengthen its support for manufacturers and suppliers across the UK’s engineering market, BCAS has continued to work with Reshoring UK and its other industrial engineering partners. Our partnership with Reshoring UK is helping our member businesses source the right engineering expertise, that can help avoid downtime, save costs and maintain the highest safety standards. Among some of the opportunities offered are:

• Connecting manufacturers with trusted, accredited UK suppliers, especially those considering domestic production for new projects or when relocating other work programmes onshore.
• Helping shorten supply chains in the UK, easing parts’ delivery and enabling faster service.
• Considering dual sourcing (where local sourcing may not be entirely possible) to mitigate for any negative future impacts.

Anderton explains that Slack & Parr’s new, purpose-built factory and headquarters in the village of Kegworth, Derbyshire, has been open for almost two years and sits adjacent to the site the company worked from for more than 100 years. “Before taking the decision to make this investment and commitment to our future here in the UK, we had a real opportunity to move production and maintenance overseas,” he says. “We chose to stay for several reasons, but mostly because the pool of engineers we recruit from here is so rich. We’re situated at the point where three counties – Nottinghamshire, Derbyshire and Leicestershire – meet. In the last century, our presence here has supported and benefitted from a community of engineering families – some with three or even four generations of family members working at Slack & Parr.

“For a business manufacturing very high precision technologies, that level of skill, knowledge and commitment is irreplaceable. Ultimately, it’s this that sustains our business and upholds the quality of our products and our reputation in the market. A century here has allowed us to build the sort of engineering community that is impossible to replicate anywhere else.”

Loeffler explains that Jubilee Clips has never actively sourced from the Far East and has remained Europe or UK focused. “Most of what we source comes from UKbased suppliers,” he says. “Nothing really comes from the Far East except for the occasional hand tools, which we source from Taiwan. Some suppliers who sourced from the Far East were understandably having difficulties during COVID.”

Increasing precision

What are our commentators’ predictions for the next year or two concerning technological developments or market trends? Anderton says Slack & Parr is seeing first-hand how technological refinement in the form of increasing precision is expanding what can be achieved in the fluid power sector and making fluid power technologies relevant in a wider variety of applications. “In our case, the launch of the FDRX and FDLX flow dividers in late 2022 is helping to broaden our share of the highperformance market,” he says. “The technology offers divisional accuracy greater than 1%, which makes it a viable and more cost-effective alternative to linear transducers and proportional valves.”

Rubinstein believes there will be even more innovation in lower carbon products, looking at the whole lifecycle approach. “For example, more compressors using VSD technology will be launched in the next couple of years, and these will optimise energy consumption even further; plus there will be developments in compressed air heat recovery technology,” he says.

Atlas Copco has already started to offer smart compressed air systems and Rubinstein points out that this trend will continue. “Whether it’s compressors that can ‘talk’ to other machines with OPC UA or controllers that receive over-the-airupdates, remote monitoring systems that send alerts to the user, or central controllers that allow them to get the most out of their compressors, Atlas Copco is already offering the products of tomorrow today,” says Rubinstein

 Jones makes the point that while it is not a new technological advancement, the need for air audits is almost certainly set to increase as operators look to optimise the energy performance of their compressors. “Often, these audits will highlight that retrofit options, such as installing heat recovery or more efficient dryer technologies, will make a positive contribution to energy efficiency, offering rapid payback,” she says.

Elsewhere, innovative compressor design is incorporating more recyclable materials into the finished product, Jones explains. “For oil-lubricated compressors, reducing the amount of oil required results in less waste oil to dispose of, for example,” she says. “BCAS members also have a key role to play, by encouraging their customers to implement thorough service regimes, with increasing numbers offering preventative and even predictive maintenance options.”

Butcher believes electronics, mechatronics, telematics and robotics will continue to play a bigger part in the industry. “Technology is moving forward with alternative propulsion systems,” he says. “Also, as we embrace the fact that battery-powered EV are not the only option – there is also hydrogen EV and hydrogen IC engine systems development in play – other industries will have to follow.”

Loeffler points out that Jubilee Clips is not looking to diversify its products to any major degree. “Our current range of clips and customised alternatives have been well-established and successful for many years,” he says. “However, we are looking to tailor more products for specific market segments, such as marine. For this sector, we are looking to produce more clips made of marine grade aisi 316 stainless steel rather than with aisi 304, which is a standard stainless steel.”

Schofield reminds us that pumps were first developed by the Egyptians around 2000 BC, and since then different types have been designed into just two main families – rotodynamic or positive displacement. “The technology within both these pump types is possibly at its peak, with only minor design changes taking place in recent years, mainly relating to efficiency levels,” he says. “The main developments have primarily revolved around how pumps are controlled, monitored, maintained, and made to operate more efficiently. This is through electrical devices such as inverters and pump system related software.”

Protecting investment

Mander reminds us that in the first quarter of 2022, short-term gas prices on the largest European exchange were five times higher than their 2021 average, and future markets are pricing European gas at up to three times its 2021 levels for at least the next three years. “However, we are advising compressed air users that action can be taken now to help protect their investments for the future,” he says. “I believe there is much that compressed air manufacturers can do to help customers during these difficult and uncertain times. We are all aware of the industry statistics around the energy usage of compressed air systems, but we can offer numerous products that can help reduce electricity costs.”

Mander stresses that there are so many different ways that customers can lower their energy costs. He maintains that, working with BCAS, it is incumbent on all members to help customers through the current energy crisis with simple and effective energy-saving advice and product solutions. Mander explains that Ingersoll Rand is predicting an increased uptake in variable-speed drive technologies. “When compared with a fixed speed compressor, a variable speed model can achieve energy savings of up to 30%, and can help reduce power surges, avoiding peak currents from starting the compressor’s motor,” he says.

Mander also expects more customers to undertake energy audits with Ingersoll Rand’s network of authorised distributors. “Whether it’s buying a new compressor or upgrading an existing system, a sensible starting point is to always undertake a full site energy audit,” he says. “This will establish current compressed air usage and costs, help identify air leaks to determine where energy is being lost and where cost savings could be made, and test air quality to ensure the compressed air generated meets the right standards. Not only does an energy audit help lower a business’ total cost of ownership, but it also helps reduce environmental impact too.”

Wright reflects that we are so used to big geo-political disturbances now that a ‘less interesting’ year would allow a retrenchment to take place and allow UK manufacturing to breath and take stock as to what its own priorities are. “We do, however, need support from government and a re-look at industrial strategy and how the Shared Prosperity Fund will interface with the manufacturing sector would be very helpful,” he says.

Cuthbert considers that in the microprocessor industry there is a steady souring and de-coupling between Western countries and China. “If this path continues, what does that mean for the fluid power supply chain and costs?” he asks. “Perhaps we are heading for two different economies working side by side, which are not competing or supplying so much to each other. This is both an opportunity for more local business but also a threat as selling into East Asia will be more difficult.”

Circular economy and lifetime costs

Sands believes increasing energy costs will force end users and then OEMs to better optimise their machine designs considering circular economy and lifetime costs, not only in terms of pounds but also CO2. “Engineers should be asking how much energy was expended in the manufacture of the parts of my machines and how can I optimise the overall CO2 consumption during use,” he says. “Digitalisation will support this, for example digital twin information will enable this information to be gathered and simulated during the design process. As digitalisation grows, we see a greater emphasis on highly flexible and transparent machine control architectures from high-level edge devices all the way down to basic actuators and sensors. Even ‘dumb’ devices will be integrated into smart systems using smart e-labels to communicate their digital twin data. Intelligent devices will become smarter to increase flexibility, with wireless commissioning, and in some cases operation, becoming more common.”

Sands adds that the chopping and changing of ministers and policy since Brexit has created a lot of confusion and wastage for industry. “A prime example is the UKCA mark where initial deadlines have been followed by staggered postponements and easements,” he says. “Whilst these are cited as being made to help trade and industry, the reality is that the strategy wasn’t clear, and insufficient consultation was made prior to the trade agreement. The result is a two-speed response, penalising the companies that responded in good time to the legislation and rewarding those who didn’t. Companies need to be agile and resilient, but a background of financial and legislative clarity and stability makes it a lot easier to invest and grow.