NEWS | FEATURES | PRODUCTS | CASE STUDIES www.pwemag.co.uk @PWEmagazine1 Implementing health and safety in manufacturing workplaces Inside this issue 12 > Smart Manufacturing Week/ Maintec Preview 20 > A maintenance manager’s guide to making the right compressor decision 36 > Why contingency planning is no longer optional page 32 @plant-&-works-engineering PWE Plant & Works Engineering Since 1981 April/May 2026 | Issue 492
Experience the cutting edge of pneumatic pressure sensing with the new PQ Cube. This advanced sensor offers: 1-inch TFT Display: Provides clear and detailed information at a glance. The full colour display ensures high visibility and clear status of the process pressure and set points. IO-Link Connectivity: Seamless integration into new or existing IO Link infrastructure, providing precise real time data, switch point status and diagnostic information helps to ensure maximum process efficiency. Our proven and incredibly robust measuring cell: Ensures proven reliability and repeatable performance even under the most arduous conditions. Simplified Assembly: The unique design allows for quick and easy installation via DIN rail or panel mounting, reducing setup time and complexity. ifm – close to you. ifm.com A revolution in pneumatic monitoring PQ Cube: Taking pressure sensing to a whole new level IT‘S NOT AUTOMATION UNTIL IT‘S ORANGE. Advert_PCCube_UK_A4.indd 1 21/10/2024 17:15 02_pwe_0526.indd 1 08/04/2026 10:24
Firms that can respond quickly through better data, flexible production or closer supplier relationships will be better placed to absorb shocks. The new reality for UK manufacturing For years, UK manufacturing has been described through a familiar set of pressures such as energy costs, skills shortages and uneven investment. That description now feels out of date. The operating environment has shifted more abruptly than many policy discussions acknowledge, and the change is being driven as much by geopolitics as by economics. The war in Ukraine was the first clear signal that supply chains were no longer simply about efficiency. The escalation of conflict involving Iran has reinforced that lesson with greater force. This is not a temporary disruption but a prolonged period of instability in the systems that underpin industrial production. Energy sits at the centre of this shift, with instability in key shipping routes Editor’s Comment ‘ ’ exposing how quickly global supply can be constrained, pushing up oil and gas prices and feeding directly into manufacturing costs, leaving UK manufacturers dealing not only with higher bills but with renewed uncertainty over pricing, margins and investment timing. The more subtle impact lies in supply chains, where disruptions to petrochemicals, logistics routes and raw materials are forcing firms to rethink long-established sourcing strategies, as lead times stretch, transport costs rise and the assumption that inputs will arrive predictably no longer holds, meaning that even where supply continues, the price and reliability of that supply have become moving targets. There is a risk in treating this as a passing shock, when the evidence points to something more structural, with successive crises from Ukraine to the current tensions in the Middle East layering on top of one another and compounding risk rather than replacing it, leading to a lasting repricing of resilience where redundancy, regionalisation and supplier diversification are no longer optional but are becoming operational necessities. For UK manufacturing, this creates both pressure and opportunity. Firms that can respond quickly through better data, flexible production or closer supplier relationships will be better placed to absorb shocks. Those that cannot may find that volatility erodes competitiveness faster than any single cost increase. The policy response remains uneven, and while there is growing recognition of the need for supply chain resilience, support is still often fragmented, with energy strategy, industrial policy and trade frameworks too often treated in isolation despite being tightly interlinked in practice. What is required now is a more realistic baseline assumption. Disruption is not an exception to be managed but a condition to be designed around. UK manufacturing is already moving in that direction. The question is whether the wider system will move with it quickly enough. April/May 2026 www.pwemag.co.uk Plant & Works Engineering | 03
AWARDS OPEN TO EVERYONE We’re celebrating the very best in the electro-mechanical service and repair industry — and every company is invited to enter. Big or small. First-time entrant or seasoned contender. If you, your company, a project, or a product/service offering is making an impact, we want to hear your story. The 2026 AEMT Awards Join the industry celebration: Thursday 19th November 2026 Doubletree by Hilton, Coventry 30th Sep Judges Convene 20th Apr Nominations Open 11th Sep Nominations Close 19th Nov Winners Announced 9th Oct Finalists Announced Entry is free of charge and multiple entries are not only allowed, but encouraged! For more information and to submit your entries, please visit: AEMTAWARDS.COM Enter one (or more) of the 10 categories: • Product of the Year • Project of the Year • Supplier of the Year • Rising Star • Diversity in Engineering • Service Centre of the Year – Large • Service Centre of the Year – Small • Electro-Mechanical Champion of the Year • Contribution to Skills and Training • Sustainable Organisation of the Year Sponsors: More sponsorship opportunities available! 04_pwe_0526.indd 1 20/04/2026 14:08
April/May 2026 www.pwemag.co.uk Plant & Works Engineering | 05 Editor: Aaron Blutstein t| 01732 370340 e| editorial@dfamedia.co.uk Content Sub Editor: Leslah Garland t| 01732 370340 e| leslah.garland@dfamedia.co.uk Sales Director: Damien Oxlee t| 01732 370342 e| damien.oxlee@dfamedia.co.uk Sales Manager: Sara Gordon t| 01732 370341 e| sara.gordon@dfamedia.co.uk Sales Manager: Andrew Jell t| 01732 370347 e| andrew.jell@dfamedia.co.uk DFA Direct: Damien Oxlee t| 01732 370342 e| damien.oxlee@dfamedia.co.uk Production Manager & Designer: Chris Davis e| chris.davis@dfamedia.co.uk Marketing Manager: Hope Jepson e| hope.jepson@dfamedia.co.uk Reader/Circulation Enquiries: Perception t| +44 (0) 1825 701520 e| cs@perception-sas.com Financial: Finance Department e| accounts@dfamedia.co.uk Managing Director: Ryan Fuller e| ryan.fuller@dfamedia.co.uk Published by: DFA Media Group 192 The High Street, Tonbridge, Kent TN9 1BE t| 01732 370340 e| info@dfamedia.co.uk w| www.pwemag.co.uk Official Supporters: Printer: Warners, UK © Copyright 2026, DFA Manufacturing Media Ltd, ISSN 0262-0227 PWE is a controlled circulation magazine, published 11 times a year. Please contact DFA Media with any subscription enquiries. Paid subscriptions are also available on an annual basis at £100.00 (UK) or £170.00 (Overseas) P+P included. The content of this magazine, website and newsletters do not necessarily express6the views of the Editor or publishers. The publishers accept no legal responsibility for loss arising from information in this publication. All rights reserved. No part of this publication may be produced or stored in a retrieval system without the written consent of the publishers. Contents 12 32 20 28 BCAS official media partner Audit Bureau of Circulation – Average net circulation 10,274 January 2024 to December 2024 COMMENT 3 NEWS 6 A round-up of what’s happening in industry. INSIGHT 10 SMART MANUFACTURING WEEK/ MAINTEC PREVIEW 12 MAINTENANCE MATTERS - INCORPORATING PROBLEM SOLVER 14 Focus on: CMMS/ Plant & Asset Management PWE looks at a new suite of AI-powered capabilities for a CMMS/EAM platform and a CMMS designed to connect machine health directly to plant performance data. PROCESS, CONTROLS, & PLANT 20 Focus on: Compressed Air/ Seals, Bearings & Lubrication Maintenance managers must decide whether to repair or replace air compressors, balancing immediate costs with long-term operational and financial performance, as explained by Rodrigo Varela, Senior Director, Aftermarket at ELGi. ENERGY & ENVIRONMENTAL MANAGEMENT 28 Focus on: Boilers, Burners, & Controls/ Net Zero PWE looks at recent activity and key developments across the boilers, burners and controls sector. HANDLING & SAFETY MATTERS 32 Focus on: Health & Safety Tom Baldwin, Large Enterprise Sector Lead for Industry at Getac UK LTD, explores some of the key aspects of effective health and safety policies in industrial workplaces that help save lives and promote long-term operational success. SPECIAL FOCUS HIRE EQUIPMENT 36 INDUSTRIAL AUTOMATION 38 PRODUCTS & SERVICES DIRECTORY 42
News 6 | Plant & Works Engineering www.pwemag.co.uk April/May 2026 UK manufacturing faces significant pressure to comply with F-Gas legislation, a challenge exacerbated by widespread ageing cooling infrastructure, volatile market conditions, and the growing threat of extreme weather. This is according to Aggreko’s latest whitepaper, Temperature Check: What Does UK Industry Need to Compete?, which surveyed 334 manufacturing plant managers responsible for cooling processes at companies with a turnover of at least £50 million. The report reveals how legislative demands, coupled with critical operational vulnerabilities, are stalling necessary upgrades and impacting the sector’s resilience. The F-gas phasedown is entering a critical stage, with proposals for a high ambition reduction pathway that accelerates cuts well beyond the current 2030 target. Under consultation, the UK aims for a 98.6% reduction in HFC use by 2048 compared to 2015 levels, supporting its Net Zero commitment. While no new product bans or changes to leak-checking and recovery requirements are currently included, the accelerated timeline will significantly influence refrigerant availability, especially those of products with a Global Warming Potential (GWP) above 1000, making the transition to low-GWP alternatives essential for future installations. “Manufacturers are facing an extremely challenging set of circumstances,” says Chris Smith, head of temperature control at Aggreko UK and Ireland. “On one hand, they’re working with ageing cooling equipment that is increasingly prone to failure, but on the other they’re being asked to meet increasingly rigorous environmental legislation. It is crucial that this equipment is upgraded to meet these legislative requirements, and site managers need further support and information to implement these changes effectively. “We are acutely aware of these challenges and commissioned Temperate Check to further analyse an often-overlooked area of the production process. In this, the impact of F-gas legislation stood out as a major talking point. The F-gas timeline is entering a decisive phase in which sharper and faster reductions could be required, and site decisionmakers require greater clarity over equipment compliance if they are to transition in good order.” The report goes on to explore factors contributing towards this impact, with knowledge and understanding of the regulations, availability of alternative solutions and the cost of the new solutions cited as major barriers to meeting the F-gas timeline. These findings are part of wider mounting concerns about ensuring sustainable production, with 97% of those surveyed saying they are facing challenges in upgrading cooling equipment to meet stricter environmental regulations. Taking this into account, Aggreko is highlighting the importance of exploring alternative equipment procurement strategies to adhere to environmental legislation while improving operational efficiency and reducing unplanned downtime. For instance, the adoption of temporary cooling systems can allow manufacturers to trial different configurations of equipment without capital expenditure restrictions while also providing flexibility to respond to seasonal peaks in production demand. “The results of this survey demonstrate that UK manufacturing is clearly under pressure and cooling is a critical part of this,” Chris concludes. “Ageing equipment, higher operating temperatures and regulatory flux are converging to create a difficult situation that plant managers may not have the budget to adequately respond to. “This is why we’re encouraging manufacturers to engage with the supply chain as early as possible and implement strategies that could help alleviate these pressures. With the right support, businesses can access efficient, scalable cooling systems that meet today’s demands without hitting the balance sheet.” To download the report please visit: https://www.aggreko.com/engb/resources/temperature-check-report UK manufacturing struggling with F-Gas compliance amid ageing infrastructure, high replacement rates and volatile markets Chris Smith, head of temperature control at Aggreko UK and Ireland Record-breaking year celebrated at the 2026 Pump Industry Awards The winners of the 2026 Pump Industry Awards were revealed at a Gala Dinner and Presentation Ceremony held on the evening of 19th March at The Hilton Hotel, St George’s Park, Burton upon Trent. Now in its 26th year, the event once again brought together leading figures from across the pump sector to celebrate excellence, innovation, and achievement. This year’s awards saw a record number of entries, underlining the continued strength, diversity, and forward-thinking nature of the industry. From cutting-edge product development to sustainability initiatives and skills advancement, the breadth and quality of submissions demonstrated a sector firmly focused on meeting the challenges of the future. Opening the evening, the BPMA President, Lee Tebbatt praised the calibre of entries and the collaborative spirit of the industry: “The Pump Industry Awards continue to showcase the very best our sector has to offer. This year’s record-breaking participation is testament to the innovation, resilience, and talent that defines our industry. Every finalist and winner should be immensely proud of their achievements.” Among the evening’s standout honours, Product of the Year, sponsored by DFA Media Group, was awarded to Selwood for its SelTank, recognised for its innovation and practical impact. Simon Finlay, Solutions and Electrical Development Director at Selwood commented: “Winning the Product of the Year Award is a tremendous milestone for the SelTank project and its journey so far. It’s a welldeserved recognition for everyone at Selwood and across the Workdry Group who helped transform a simple sketch of an idea into an award-winning innovation. In the Environmental Contribution of the Year category, sponsored by SPP Pumps, ABB took top honours for its IE5 Synchronous Reluctance (SynRM) Motor Range, highlighting the growing importance of energy efficiency and sustainability. Metcor Pumps was named Distributor of the Year, jointly sponsored by Calpeda and Caprari, while John Crane received the ABB
News April/May 2026 www.pwemag.co.uk Plant & Works Engineering | 07 Manufacturing has been central to the UK’s economic strength for more than a century, and as Make UK marks its 130th year, the sector finds itself at another pivotal moment. Founded in the Glasgow shipyards and shaped by generations of engineers, innovators and employers, MakeUK has always existed to champion the makers of this country. That mission remains unchanged, and is more vital than ever. Its latest report, The Shape of British Industry, reflects a sector that has evolved dramatically over the last decade. Manufacturers have faced profound geopolitical, economic and technological shifts, yet have responded with resilience, agility and ambition. Companies are investing at pace in digital technologies, AI and advanced automation; modernising factories; strengthening supply chains; and building the capabilities needed to remain competitive in an increasingly demanding global environment. At the same time, longstanding challenges, such as skills shortages, high energy costs, and inconsistent regulatory and tax frameworks, continue to constrain the UK’s competitiveness and limit the scale of investment our country should be attracting. The global context has changed fundamentally. The relative stability of recent decades has given way to a more complex, more contested world in which economic security and industrial strength are increasingly inseparable. For the UK, this presents both challenge and opportunity. To thrive, we must build a more resilient industrial base, strengthen strategic supply chains, and foster the conditions for worldleading innovation. Above all, this requires delivery: consistent, longterm policy that endures beyond political cycles and gives businesses the confidence to invest. The findings in the report underline the priorities shared across UK manufacturing: a skills system aligned to advanced industry; competitive and predictable energy costs; a modern, streamlined regulatory environment; and the delivery of an industrial strategy that provides clarity and direction. Manufacturers are ready to invest, ready to innovate and ready to lead the transition to a more digital, more sustainable and more productive economy. But they need a policy environment that matches their ambition. The UK’s history has shown that when the UK backs its makers, they deliver, from breakthrough technologies to worldclass exports and highvalue jobs in every region of the country. Looking ahead, manufacturing has a central role to play in building a stronger, more secure and more resilient economy. We hope this report provides a clear foundation for that partnership between industry and Government, and a shared understanding of what is required to unlock the full potential of British manufacturing. By MAKE UK chief executive, Stephen Phipson MAKE uk - the manufacturers’ organisation monthly news comment sponsored Contribution to Skills & Training Award for its partnership with The University of Sheffield, underlining the sector’s investment in future talent. The Project of the Year award, sponsored by World Pumps, went to Baker Hughes for its Reliable Pumping Solution for Combined Cycle Plants, a project demonstrating engineering excellence from design through to operation. One of the most prestigious accolades of the evening, Manufacturer of the Year, sponsored by WEG UK, was awarded to SPP Pumps, recognising its outstanding performance and industry leadership. Meanwhile, WEG UK was also celebrated as the winner of Supplier of the Year, sponsored by Wilo. The next generation of talent was recognised in the Rising Star Award, sponsored by Innomotics, with Luke Norris of John Crane UK taking the title. Reflecting on his achievement, Norris said: “It’s a huge honour to be recognised among such talented peers. This industry offers incredible opportunities, and I’m excited to be part of its future.” The Sustainable Contribution for a Better World Award, sponsored by AESSEAL, was presented to Apex Pumps, acknowledging its commitment to environmental responsibility and innovation. Another sponsor, Patrick Tantum, Group Director, UK & Ireland at Calpeda and Caprari, summed up the evening’s significance: “We are honoured to support the BPMA’s Pump Industry Awards programme, which continues to showcase the very best of innovation, engineering excellence, and collaboration across our sector. It was a pleasure to be part of the evening once again, bringing the industry together to recognise success, reconnect with peers, and highlight the strength of the community behind it. Not only does it celebrate achievement, but also sets the benchmark for standards, drive progress, and inspire the next phase of growth within our industry. We are proud to play our part in supporting that journey.”
News 08 | Plant & Works Engineering www.pwemag.co.uk April/May 2026 BCAS launches new Compressed Air Management certified training programme The British Compressed Air Society (BCAS) has launched its updated and flexible Compressed Air Management certified training programme, which has been approved by the Society of Operations Engineers (SOE) The programme compresses a suite of individual units, each relevant to specific industry needs to help learners undertake smaller and more targeted learning when it is needed. This training then builds into an award, a certificate or, over time, the full Diploma in Compressed Air Management (DipCam). Terry Coller, BCAS Training and Development Officer explains: “Our previous DipCam course has been a compressed air industry staple for many years, providing comprehensive training on a wide range of compressed air competencies, from system components to installation to maintenance to name a few. However, individuals needed to commit significant time from their day-to-day routines to study for the full diploma, with no other awards offered in between. “The new Compressed Air Management certified training programme offers a completely different approach, with units assigned a credit value We have designed it to be flexible and to cater for as many learning needs and styles as possible. Each individual unit can be purchased and studied individually, and certification will be issued upon a satisfactory result from the short test at the end of each unit. “For example, to achieve the entry-level award certification, learners need to attain two mandatory units and two optional units. To gain the full diploma, participants study five mandatory units and five optional units. “Mandatory units include safety considerations, compressors and compressed air treatment to name a few, while optional units cover air receivers, pneumatics, legislation and safety standards, system design and energy efficiency. “But we haven’t finished yet. We are already in the advanced stages for two additional units to be added to this suite, ensuring we continue to meet the evolving needs of the compressed air sector.” The Society of Operations Engineers (SOE) has also approved the full suite of courses, confirming they meet the rigorous standards for Continuous Professional Development (CPD). Terry concluded: “The new Compressed Air Management certified training programme has been created with the help of many of our members. Not only have they contributed their technical expertise to ensure that each unit explains core subjects in detail, but they have helped ensure that the new programme delivers the correct level of training that is both meaningful to the learner and of benefit to the wider industry.” To learn more about the new, modular layout, please visit: https://elearning.bcas.org.uk/new-compressed-airmanagement-qualification-course/ Cochran bolsters its team with senior appointment Leading industrial boiler specialist, Cochran, has appointed Leigh Freeman as Head of People and Culture. Based at its headquarters in Newbie in South-West Scotland, Leigh will lead on the company’s recruitment, people strategy, talent development and culture. She brings more than 30 years’ experience in HR and recruitment to this newly created role and holds an MA in Human Resource Management, a NEBOSH general certificate, and is a qualified workplace mediator and Fellow of the CIPD (FCIPD). Most recently Leigh worked at Make UK, a membership organisation for the manufacturing industry where she provided HR consultancy to members. She oversaw the full HR function - from delivering targeted leadership training to guiding businesses through complex organisational change and site closures - and worked with owner-led companies, SMEs and global organisations. Leigh has also held senior in-house roles including Head of People and HR Manager positions in manufacturing and construction organisations. Leigh’s expertise and strategic outlook will benefit Cochran as she spearheads aligning the company’s talent strategy with business growth. She will lead the company’s people and culture strategy and help to enhance employee engagement and attract future talent. Leigh said: “I’m excited to be joining as Head of People and Culture in a new role that underlines Cochran’s commitment to putting its people first. “I’ve had the pleasure of getting to know and supporting the senior team over the last few years in a consultancy role and this has given me a clear insight into the company’s culture and ambitions. I’m really forward to building on the strong foundations already in place and helping to shape the next phase of growth. Tom Ritchie, Managing Director of Cochran commented “We are delighted to welcome Leigh to the team. From the work she has done with us to date it’s clear to see Leigh is highly motivated, with great integrity and a passion for people. “We are proud of our heritage and track record as a key employer in our region and are dedicated to providing opportunities and training to the next generation. Leigh’s appointment will help us to continue to attract and develop best in class talent.”
April/May 2026 www.pwemag.co.uk Plant & Works Engineering | 9 Advertorial Precision in close-tolerance part design results from aligned decisions across design, materials science, and manufacturing. A single misstep in any area can cascade into scrap, rework, and cost overruns. Design for manufacturability connects those decisions and keeps production viable. This guide draws on the expertise of Fisher Barton, a Watertown, Wisconsin-based manufacturing group with over 100 years of experience producing complex components for OEMs and industrial manufacturers worldwide. The aim is to help companies improve their accuracy during production and create topquality products. Foundational Principles of CloseTolerance Part Design Design success begins long before a spindle turns. Engineers who overspecify tolerances on nonfunctional features drive up machining time and cost without improving part performance. Tolerance stack-up analysis addresses this directly by mapping how individual dimensional variations accumulate across an assembly. It reveals which features genuinely require micronlevel precision. A study confirmed that systematic tolerance optimisation delivers significant cost reductions over equal-tolerance allocation. Prioritise critical mating surfaces, and relax specifications everywhere else. Material selection runs in parallel with the tolerance strategy. An item’s coefficient of thermal expansion, machinability, and stressrelief behaviour all influence whether a part holds its dimensions through a full production run. Engineers who select alloys based only on end-use mechanical requirements often find that material expands unpredictably under machining heat. Evaluating dimensional stability from the outset eliminates an entire category of downstream failure. Optimising the Manufacturing Environment for Precision The physical environment where machining takes place directly affects dimensional outcomes, even when the equipment and tooling are fully capable. Maintaining Thermal Stability Heat is the primary cause of dimensional inconsistency in close-tolerance machining. A small temperature rise can push a precision steel part beyond tolerance limits in highaccuracy applications. The international standard measurement temperature is 20° Celsius (68° Fahrenheit), and leading precision manufacturers hold their environments as close to that benchmark as possible. Ensuring Machine and Tool Integrity A stable environment delivers diminishing returns if the machines within it aren’t calibrated daily. CMMs, CNC machining centres, and precision grinding equipment all develop measurement and positioning drift over time. Rigid workholding fixtures that distribute clamping forces evenly are equally important. Even a few microns of part movement under cutting forces will produce parts that are consistently out of specification, with no obvious cause visible to the operator. Integrating Material Science Into Design True design for manufacturability accounts for how materials behave under heat and stress. This is where a knowledgeable partner delivers true value. Fisher Barton’s material-sciencebacked approach addresses the three challenges that frequently drive up cost and scrap in close-tolerance work: High manufacturing costs: Unnecessary complexity and overtoleranced surfaces increase cost at every machining step. Early collaboration helps to identify design adjustments that simplify machining paths or to substitute a more cost-effective yet equally stable material. Scrap reduction manufacturing: Scrap follows predictable patterns tied to material behaviour under stress and thermal response during extended runs. Fisher Barton’s expertise structures the machining sequence to account for these patterns. Complex close-tolerance part design: Many manufacturers decline projects because the combination of material, tolerance, and form exceeds what a generalist shop can reliably produce. Fisher Barton’s depth of material knowledge allows the team to take on these projects and build a production path that makes them repeatable and efficient. Advanced Machining and Quality Control Execution is a process discipline when working with a well-engineered design. Dedicated roughing tools remove bulk material quickly, while separate finishing tools preserve edge geometry and surface quality on final passes. In-process metrology using CMMs and laser scanners catches dimensional deviations as they develop, rather than after an entire run is compromised. Investing in Precision Pays Off Achieving close-tolerance accuracy benefits organisations that address it systematically. This compounding effect ensures batch conformance, sustained scrap reduction, decreased rework, and stronger long-term supplier relationships. https://www.fisherbarton.com/capabilities /close-tolerance-machining/ The Practical Guide to Achieving Accuracy in Close-Tolerance Engineering
10 | Plant & Works Engineering www.pwemag.co.uk April/May 2026 Insight Hydraulic systems have a habit of revealing their problems gradually. Long before a pump fails or a valve begins to respond sluggishly, the warning signs are often already circulating within the oil itself. A rise in particle levels, traces of water, subtle changes in viscosity or increasing oxidation can all signal that wear or contamination is developing somewhere inside the circuit. For engineers responsible for keeping plant running, lubrication is therefore more than a routine maintenance consideration; Reducing downtime by managing hydraulic lubrication and contamination Hydraulic oil does far more than transmit power, its condition reflects the health of the entire system, influencing efficiency, component life and reliability. As hydraulic equipment across UK industry operates under higher pressures and stricter environmental expectations, careful management of lubrication and fluid cleanliness has become essential to maintaining performance and preventing costly failures. PWE reports. it is a direct indicator of system health. As system pressures and power densities have increased over the past two decades, the tolerance for poor lubrication practices has decreased. Components such as piston pumps and proportional valves are manufactured with extremely fine internal clearances and depend on clean, stable hydraulic oil to function correctly. Hydraulic oil performs several roles simultaneously. It transmits power throughout the system, lubricates moving surfaces, removes heat generated during operation and protects internal metal components against corrosion. A failure in any one of these functions affects the others. When oil becomes contaminated or chemically degraded, friction increases, temperatures rise and wear accelerates inside pumps, motors and valves. Solid particle contamination remains the most common cause of hydraulic wear. Dirt introduced during maintenance, airborne dust entering through reservoir breathers or wear debris generated inside the system can all
Insight April/May 2026 www.pwemag.co.uk Plant & Works Engineering | 11 damage critical components. Once particles begin circulating through the circuit they create further wear, generating additional debris that progressively worsens the condition of the oil. Contamination control Because of this, contamination control has become one of the most important aspects of hydraulic maintenance. Increasingly, operators are recognising that oil supplied in drums or bulk containers is rarely clean enough to meet the requirements of modern hydraulic systems. Filtering oil during transfer into the machine has become standard practice in many maintenance workshops. Cleanliness levels are normally defined using ISO 4406 particle counting codes. Highpressure hydraulic systems that incorporate piston pumps or servo-controlled valves often require oil cleanliness around ISO 17/15/12 or better to maintain reliable operation. Achieving these levels consistently requires carefully designed filtration strategies. Pressureline filters provide direct protection for sensitive components, while return-line filters capture wear particles before the oil returns to the reservoir. Large hydraulic systems frequently benefit from offline filtration circuits, sometimes known as kidney-loop filtration. These systems continuously circulate oil through a dedicated filter independent of the main hydraulic circuit. Over time this approach can significantly reduce contamination levels and stabilise fluid cleanliness, particularly in systems with large oil volumes. Water contamination presents a different but equally serious problem. Moisture may enter hydraulic reservoirs through damaged seals, poorly protected breathers or condensation forming inside tanks during temperature fluctuations. Even small quantities of water reduce the lubricating properties of hydraulic oil and accelerate chemical degradation. Oxidation of the base oil increases acidity, leading to varnish formation and corrosion of internal components. To prevent moisture ingress, many hydraulic reservoirs are now fitted with desiccant breathers that remove water vapour from incoming air. Improved reservoir sealing and controlled oil storage conditions also play an important role. Where water contamination has already occurred, vacuum dehydration systems are capable of removing both free and dissolved water from hydraulic fluids. These technologies are widely used in heavy industry and offshore installations where large oil reservoirs make complete fluid replacement impractical. Oil analysis programmes Oil analysis programmes provide another valuable tool for maintaining hydraulic system health. Regular sampling and laboratory testing allow engineers to monitor the condition of the oil and detect early signs of component wear. Particle counting reveals contamination levels, while elemental analysis can identify metals such as iron, copper or aluminium that originate from specific components. Monitoring viscosity and acid number provides insight into the chemical condition of the oil itself. Using this information, many operators have moved away from fixed oil-change intervals. Instead, maintenance decisions are increasingly based on the measured condition of the fluid. When contamination is well controlled, hydraulic oils can remain in service for extended periods without compromising reliability. Conversely, early detection of abnormal wear allows maintenance teams to investigate developing faults before they lead to equipment failure. Leakage remains another issue affecting hydraulic system performance. External oil leaks are usually obvious and can pose environmental or safety concerns. Internal leakage, however, is more difficult to detect. As internal surfaces wear within pumps or cylinders, hydraulic oil begins to bypass sealing surfaces. The system may continue operating, but pressure stability declines and efficiency drops. Monitoring pressure behaviour and flow characteristics can reveal the presence of internal leakage. A pump that struggles to maintain pressure under load or generates excessive heat may be experiencing internal wear rather than a simple external fault. Identifying such issues early helps maintenance teams plan repairs in a controlled way rather than responding to unexpected breakdowns. Environmental considerations are also influencing lubrication strategies in the UK. Equipment used in ports, inland waterways and offshore installations must operate with minimal risk of environmental contamination. Hydraulic oil spills can lead to costly remediation work as well as regulatory scrutiny. For this reason, environmentally acceptable hydraulic fluids are increasingly specified in sensitive environments. Many of these fluids are based on synthetic esters that degrade more readily in natural conditions while still providing strong anti-wear performance and oxidation resistance. Standards such as ISO 15380 define performance requirements for biodegradable hydraulic fluids used in environmentally sensitive applications. Renewable energy infrastructure illustrates how lubrication requirements are evolving. Offshore wind turbines rely on hydraulic systems for blade pitch control and maintenance equipment. These systems must operate reliably for long periods in harsh marine environments where moisture and temperature variation can affect fluid stability. Selecting hydraulic oils with strong oxidation resistance and excellent water separation characteristics is essential to ensure long service life. Mobile hydraulic equipment presents different challenges. Construction and infrastructure machinery frequently operate in dusty environments and under fluctuating loads. Maintaining fluid cleanliness in these conditions requires robust filtration, well-designed sealing and disciplined servicing practices. Portable filtration units and onsite oil analysis equipment are increasingly used to support maintenance teams working on remote sites. Energy efficiency has also become a growing concern in hydraulic system design. Hydraulic power remains one of the most effective ways to transmit large forces, but energy losses can occur through internal leakage, fluid friction and heat generation. Maintaining clean oil with stable viscosity helps minimise these losses and allows pumps and valves to operate closer to their intended efficiency. Synthetic hydraulic oils Synthetic hydraulic oils are often used where temperature stability and efficiency are particularly important. Their higher viscosity index allows them to maintain consistent lubrication performance across a wide temperature range, improving cold-start behaviour while maintaining adequate protection at higher operating temperatures. The practical lesson for engineers is straightforward. Hydraulic oil should be treated as an active component of the system rather than a consumable that receives attention only during routine servicing. When contamination is controlled, fluid condition is monitored and the correct lubricants are selected, hydraulic equipment operates more efficiently and components last significantly longer. In industries where reliability is critical and downtime carries significant cost, the condition of the oil circulating through hydraulic systems remains one of the clearest indicators of how well those systems are being managed.
12 | Plant & Works Engineering www.pwemag.co.uk April/May 2026 Smart Manufacturing Week/Maintec Preview These issues will form the basis of Smart Manufacturing Week (SMW), which returns to the NEC Birmingham on 3-4 June 2026 for its fifth edition. Commenting on the show’s previous edition, returning exhibitor Daniela David, Field Marketing Specialist at IFS Ultimo, said: “In my view, industry events are more than just leadgeneration opportunities. The energy and synergy before and during the event are the real drivers of success. For me, it’s the collaboration, the engagement, the learning, and the exchange of valuable insights that are the true gold. Maintec, as part of Smart Manufacturing Week, was exactly that.” Structuring around sector priorities The 2026 programme is organised around five strategic pillars: Digital Transformation Sustainability and Circular Economy Supply Chain Resilience Innovation and Smart Technologies Workforce and Skills The framework reflects ongoing external pressures, including tariffs, geopolitical Smart Manufacturing Week 2026 to address sector-wide transformation challenges The UK manufacturing sector continues to operate under increasing pressure from digitalisation, supply chain instability and the transition to Net Zero. For many organisations, the priority is no longer identifying these challenges but determining how to respond in a structured and commercially viable way. PWE reports. uncertainty and energy costs, all of which continue to affect supply chain stability. In this context, manufacturers are being required to strengthen risk awareness, improve responsiveness and maintain continuity while meeting customer expectations. Alongside these operational challenges, the sector continues to face a skills shortage. An ageing workforce and persistent misconceptions about manufacturing careers are contributing factors. As a result, many organisations are placing greater emphasis on upskilling, training and building more diverse, future-ready teams. Technical content and applied insight The event will feature more than 170 free-toattend sessions delivered across eight Solution Theatres. The programme is designed to focus on implementation and application, rather than high-level discussion. Key topics include: AI-driven productivity and machine learning applications The deployment and practical value of digital twins Strategies for Net Zero manufacturing Workforce transformation and skill development in the automation era By focusing on applied technologies and operational outcomes, the sessions are intended to provide attendees with insights that can be directly translated into practice. Co-located events across the manufacturing lifecycle Smart Manufacturing Week brings together six co-located events: Smart Factory Drives & Controls Maintec Design & Engineering The Manufacturer Top 100 Manufacturing Digitalisation Summit This structure reflects the interconnection between different stages of manufacturing, from design through to maintenance. For example, the performance of a smart factory is closely linked to the maintenance and asset management strategies associated with Maintec. The Manufacturing Digitalisation Summit is expected to attract senior representatives from organisations including AstraZeneca, RollsRoyce, Jaguar Land Rover, Airbus and Atlas Copco. In 2025, the event welcomed more than 13,500 attendees from across manufacturing, engineering and technology sectors. Chris Allen, Marketing Manager of Smart Manufacturing Week, noted the event’s unique value in the market: “Smart Manufacturing Week is the one moment each year where our whole industry comes together - not just to showcase technology, but to share ideas, solve problems and genuinely connect. It’s a place where conversations spark innovations.” New features for 2026 The 2026 edition will introduce new features aimed at increasing engagement. One addition is Fight Fest, a robotics competition located within the Drives & Controls section and hosted
Smart Manufacturing Week/Maintec Preview on the Accu Bots stand. The competition will feature both student teams from across the UK and professional participants, focusing on areas such as mechanical design, programming and prototyping. While positioned as an interactive feature, it also reflects the importance of engaging the next generation of engineers. Expanded networking and targeted engagement The Ambassador Programme will return in an expanded format, providing structured opportunities for individuals to connect and collaborate on shared industry challenges. In addition, a dedicated networking platform will enable attendees to arrange one-to-one meetings in advance. Supported by matchmaking services and on-site assistance, the system is designed to help participants identify relevant contacts more efficiently. Industry participation and outlook Exhibitors confirmed for 2026 include Beckhoff, Solutions PT, Epicor, Ericsson, Prod Utech, Fanuc and Sage. Grace Gilling, Event Director at Smart Manufacturing Week said: “Smart Manufacturing Week 2026 is all about bringing the future of advanced manufacturing and engineering to life. This year, we’re introducing brand-new features designed to showcase the very best the industry has to offer. “Our Meet the Buyer programme helps visitors source the most efficient and profitable solutions for 2026, ensuring every moment delivers real value. “The Future Stage will showcase breakthrough thinking and bold ideas from pioneering innovators, offering debate on the strategies shaping the next decade. Plus, the expanded Ambassador Programme brings more industry leaders for enhanced networking, learning, and inspiration. “Together, these features make Smart Manufacturing Week 2026 an ever-growing festival for all facets of industry. It’s the destination for industrial transformation and a glimpse of what manufacturing and engineering can achieve.” Further announcements, including keynote speakers, are expected in the coming weeks. Registration is now open via the Smart Manufacturing Week website: www.smartmanufacturingweek.com Claim your FREE monthly digital subscription For the latest news and techology visit our website NEWS | FEATURES | PRODUCTS | CASE STUDIES April/May 2025| Issue 486 www.pwemag.co.uk @PWEmagazine1 The importance of energy efficiency for industrial ESG goals Inside this issue: 10 > Smart Manufacturing Week/ Maintec Preview 14 > Bridging the gap between CMMS & emerging technologies 28 > The rise of the electric thermal fluid heater page 30 @plant-&-works-engineering PWE Plant & Works Engineering Since 1981 www.pwemag.co.uk
Maintenance Matters Focus on: CMMS 14 | Plant & Works Engineering www.pwemag.co.uk April/May 2026 Fluke Corporation has introduced a new suite of AI-powered capabilities for its eMaint CMMS/EAM platform. Now available in beta to eMaint customers, these enhancements embed purpose-built artificial intelligence directly into daily maintenance workflows. The new features enable teams to quickly access and analyse asset data, convert asset documentation into actionable tasks and procedures, and generate work requests using voice input. Designed for practical, real-world application rather than complex experimentation, the innovation was designed specifically from customer feedback of what slows them down every day. The beta features underscore Fluke’s focus on delivering AI that drives immediate value on the plant floor. “With this new version of eMaint, we’re bringing the power of artificial intelligence directly to maintenance professionals who keep operations running,” said Jay Hack, General Manager, Fluke Corporation. “This beta release isn’t about experimentation. It’s about transforming the way maintenance work gets done by turning complex data and manuals into actionable insights, while helping teams make smarter, faster decisions. It marks a new era in maintenance management by redefining what efficiency and reliability look like across the industry.” The beta release introduces several highimpact AI capabilities designed to drive faster decisions, safer execution, and greater workforce efficiency. Instant answers from your own maintenance data: Talk to your data and instantly surface summarised insights across work orders, assets, parts, and maintenance history — all in one place. Refine, filter, or tailor AIgenerated responses to focus on what matters most, and access AI-powered answers drawn from your documents and maintenance data directly in the eMaint mobile app, complete with voice input and hands-free support for technicians in the field. Smarter work execution: SOP Builder autogenerates standard operating procedures and preventive maintenance tasks from manuals, document repositories, and other technical documents, which can reduce PM creation time by 50% or more. Once created, eMaint can prompt technicians to follow critical steps, improving consistency, safety, and knowledge capture across teams. Documentation made actionable: The AI capabilities in eMaint transform complex Original Equipment Manufacturer manuals into concise, on-demand guidance. This enables technicians to ask direct questions and receive clear, multilingual answers that boost speed and confidence across skill levels. It also enables hands-free work order creation via voice, automatically translating recordings into structured work order requests so issues are captured instantly in the flow of work. The release comes at a time when maintenance organisations face increasing pressure from skills gaps and workforce turnover. As experienced technicians retire, capturing and distributing knowledge has become a growing challenge across assetintensive industries. Fluke says its beta version of eMaint is already transforming maintenance in logistics and manufacturing by delivering faster access to documentation, clearer insights from complex manuals, and mobile-ready support. Designed to fit seamlessly into existing workflows, the first-generation release helps technicians work more efficiently without needing AI expertise. By simplifying information access and promoting consistent task execution, the technology augments—not replaces— human expertise, enabling teams to focus on higher-value problem-solving. The capabilities are available now in beta to select customers, with broader rollout planned after continued refinement. For further information on eMaint, please visit: https://www.fluke.com/ en-us/products/fluke-software/emaint-cmms AI powered features transform maintenance workflows CMMS launch connects machine health with plant performance Nulogy has launched Nulogy Maintenance, a computerised maintenance management system (CMMS) designed to connect machine health directly to plant performance data. In most manufacturing environments, maintenance and production run on separate systems. The gap creates a predictable failure mode where machines are over-or underserviced, unplanned downtime becomes a costly burden, and it’s difficult to prove whether maintenance activity directly improved output. Nulogy Maintenance eliminates these challenges by bringing both into a single ecosystem. Maintenance orders are automatically triggered by machine condition signals, usage data, and operator requests, rather than fixed calendar schedules, ensuring
Focus on: CMMS Maintenance Matters April/May 2026 www.pwemag.co.uk Plant & Works Engineering | 15 machines are serviced exactly when needed, not before or after. Work is prioritised by asset criticality and live line impact, so teams focus where it matters most. “Unplanned downtime doesn’t just disrupt your shift; it hits your costs, your output, and your customers. Nulogy Maintenance gives us the visibility to stay ahead of it. We know what our machines need, when they need it, and we can see exactly how that’s improving our performance,” said Bennett Bishop, Director of Operations & Finance, Ice Industries. Because maintenance and production data share the same system, manufacturers can see directly how maintenance activity improves output over time. It is available as a native solution within Nulogy’s Manufacturing Operating System (MOS) and connects with existing systems such as ERP and MES, enabling manufacturers to extend and enhance their current technologies. “The power of Nulogy Maintenance lies in its connectivity with every other aspect of the manufacturing lifecycle,” said Bill Ryan, CEO, Nulogy. “When maintenance and production share the same data, manufacturers can stop reacting and start preventing. Plants that run reliably are plants that grow.” Hundreds of manufacturing sites around the world, including industry leaders such as Ice Industries, Louisiana Fish Fry, Autoliv, Summit Packaging Solutions, and McCloskey International, run on Nulogy’s Manufacturing Operating System. Nulogy helps manufacturers, packers, and brands run operations more predictably by connecting how work is executed across their manufacturing and supply chain networks. With more than 20 years of experience supporting hundreds of co-packing, contract manufacturing, and discrete manufacturing operations worldwide, Nulogy is trusted by many leading organisations. For further information please visit: www.nulogy.com TECHNICAL TRAINING SOLUTIONS Providing Practical Electrical, Instrumentation & Mechanical Skills Training for Industry since 1980 LEARNING BY DOING technicaltrainingsolutions.co.uk tech.training@zen.co.uk 01634 731 470 PWE 1.4 MASTER 2025.indd 1 07/04/2026 15:29:58
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