Metso Outotec has been awarded a contract to deliver sustainable grinding technology to an iron ore project producing premium pellet feed in South America. The total value of the order exceeds EUR 10 million, and it has been booked in Minerals’ Q2/2022 orders received.

Metso Outotec’s scope of delivery consists of the engineering, manufacturing and supply of four Vertimill® vertical grinding mills. In addition, Metso Outotec will provide installation and commissioning advisory services. The Planet Positive Vertimill® grinding mills are expected to save more than 30% of the installed power compared to a conventional ball mill circuit.

“We are pleased that our customer has chosen the industry-leading Vertimill® technology. The regrinding circuit will enable energy-efficient grinding combined with low operating and life-cycle costs,” says Christoph Hoetzel, Head of the Grinding business line at Metso Outotec.

More information about Metso Outotec’s minerals processing technologies is available on our website.

Further information, please contact:

Fernando Samanez, Vice President, Minerals Sales, South America, Metso Outotec, tel. +51 9 97583694, email: fernando.samanez(at)mogroup.com

Metso Outotec is a frontrunner in sustainable technologies, end-to-end solutions and services for the aggregates, minerals processing and metals refining industries globally. By improving our customers’ energy and water efficiency, increasing their productivity, and reducing environmental risks with our product and process expertise, we are the partner for positive change. Metso Outotec is committed to limiting global warming to 1.5°C with Science Based Targets.

Headquartered in Helsinki, Finland, Metso Outotec employs over 15,000 people in more than 50 countries and its sales for 2021 were about EUR 4.2 billion. The company is listed on the Nasdaq Helsinki. mogroup.com,

With the certification of BASF’s production site in Cassina Rizzardi, Italy, BASF is the first chemical company offering certified sustainable personal care ingredients based on coconut oil. The company was certified according to the Rainforest Alliance Mass Balance Coconut certification scheme. Mass balance (MB) is a supply chain model that fosters the physical flow of certified raw materials within the supply chains, while the farmers benefit from selling Rainforest Alliance Certified coconuts and copra.  

“With the certification of our first production site and the offer of Rainforest Alliance Certified personal care ingredients to our customers, amongst palm and castor oil, we have established another supply chain based on renewables. We have thus taken an important step in transforming the market towards certified, sustainably sourced oleochemicals”, said Jutta Stute Sustainability Manager in BASF’s Care Chemicals division.

Coconut oil is an important feedstock for the chemical industry. BASF uses coconut oil to produce ingredients for cosmetic products, detergents and cleaning agents as well as foodstuff.

BASF is first to offer personal care ingredients based on certified sustainable coconut oil.

Certified sustainably sourced coconut oil is just one recent example of how BASF’s Care Chemicals Division is addressing future challenges. Sustainability, digitalization, innovation and new approaches to working together are the key cornerstones to Care 360° – Solutions for Sustainable Life. 

The certification of coconut oil was made possible by a development partnership between BASF, Cargill, The Procter & Gamble Company (P&G) and the German government agency Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH with the strong support from the Rainforest Alliance and the Philippine Coconut Authority. The objective of the project was to increase the income and economic self-sufficiency of smallholder coconut farmers in the Philippines and Indonesia by promoting a sustainable certified coconut oil supply chain. Between November 2015 and October 2018 more than 4,100 coconut farmers were trained in good agricultural practice (GAP), good processing practice as well as farm management. About 1,600 farmers received additional training and have been certified according to the Rainforest Alliance Sustainable Agriculture Standard. Farmers who were trained and certified have, on average, a 47 percent higher income than farmers who did not participate in the program.

BASF has set itself the goal to creating chemistry for a sustainable future. As a worldwide acting company, BASF has a responsibility to manage its supply chain carefully. The company is deeply involved in a range of initiatives to increase the share of nature-based ingredients in its portfolio and to enhance the sustainability of farming practices and the well-being of farmers and workers. Examples include the Roundtable on Sustainable Palm Oil (RSPO) as well as SuCCESS (Sustainable Castor Association).

Visit https://www.basf.com/global/en/who-we-are/sustainability/we-source-responsibly/sustainable-coconut-oil-production.html for more details.

About BASF

At BASF, we create chemistry for a sustainable future. We combine economic success with environmental protection and social responsibility. Around 111,000 employees in the BASF Group contribute to the success of our customers in nearly all sectors and almost every country in the world. Our portfolio comprises six segments: Chemicals, Materials, Industrial Solutions, Surface Technologies, Nutrition & Care and Agricultural Solutions. BASF generated sales of €78.6 billion in 2021. BASF shares are traded on the stock exchange in Frankfurt (BAS) and as American Depositary Receipts (BASFY) in the U.S. Further information at www.basf.com.

About the Care Chemicals division at BASF

The BASF division Care Chemicals offers a broad range of ingredients for personal care, home care, industrial & institutional cleaning, and technical applications. We are a leading global supplier for the cosmetics industry as well as the detergents and cleaners industry, and support our customers with innovative and sustainable products, solutions and concepts. The division’s high-performance product portfolio includes surfactants, emulsifiers, polymers, emollients, chelating agents, cosmetic active ingredients and UV filters. We have production and development sites in all regions and are expanding our presence in emerging markets. Further information is available online at www.care-chemicals.basf.com.

Many industries have embraced the push for digital transformation in recent years to meet the increasing demands for high levels of safety and traceability across global supply chains. The food and beverage industry is no different, with many working to retire outdated software and inefficient paper-based systems that limit visibility and hamper performance improvements across their production facilities.

Cloud-based Software-as-a-Service quality management solutions make this shift easier than ever, offering rapid and simple deployment, low up-front costs and flexible scalability. Food manufacturers can gain access to critical insights whenever and wherever they are needed most in order to maintain product quality, ensure compliance and drive continuous improvement across their organisations.

Centralising data improves visibility and collaboration

Jason Chester - Direcctor of Global Channel ProgramsIn a traditional manufacturing environment, quality and process data are often locked away in paper files, Excel spreadsheets, or legacy on-premises software. These prevent manufacturers from monitoring enterprise-wide quality performance and inhibit data sharing with external parties across the supply chain. Cloud solutions provide a single, unified data repository where food manufacturers can standardise and centralise quality data—from all processes, production lines, and sites in their enterprise.

The resulting “big picture” view of quality enables food companies to perform enterprise-wide analyses to pinpoint problem areas, identify best practices, and prioritise resources. Ongoing regulatory compliance can be verified and accountability for all checks can be easily enforced. Ultimately, this can improve quality and compliance across the entire organisation.

Additionally, viewing supplier data in real-time to prevent food safety issues becomes possible, and manufacturers can ensure incoming ingredients meet quality standards before they are ever shipped. Only the highest-quality ingredients get accepted and incorporated into products, helping uphold your overall brand standards. Supplier performance is also easy to monitor and therefore enables any disruptions to be more easily prevented or managed when they might arise.

Respond proactively on the plant floor

A preventative approach to quality and safety just isn’t possible when using manual methods for data collection and analysis. Operators spend valuable time recording data with a pencil and paper, then sift through page after page of control charts—on top of all their other daily responsibilities. It’s easy to see how mistakes could be made and production issues could be missed.

Quality teams are also at a disadvantage, reviewing historical data about products that have already come off the production line. They act one step behind, and often by that point it’s too late. Some problems may not be identified until the final inspection, if even caught at all. Manufacturers end up dealing with defective products, wasted resources, and damaging recalls.

Cloud-based statistical process control (SPC) software can automatically collect measurement values from a variety of data sources, and then monitor processes in real-time. When the software detects specification or statistical violations, automated alarms instantly alert key personnel, allowing them to take immediate action to correct any issues.

Further safeguards can be placed using workflows – prescriptive guides for responding to quality issues that are predefined in the cloud-based quality solution. Employees can respond consistently to problems and then document the corrective actions for analysis across the entire company. This in turn allows manufacturers to spot any trends and prevent reoccurring issues on a wider level.

Routine keeps everyone on the same page

Routine sampling and quality checks are critical for food safety and compliance with regulatory and industry-specific standards. But how can manufacturers ensure required checks are completed according to schedule? In times when the plant floor is busy, it can be easy for operators to get side-tracked tackling other issues.

With cloud-based quality systems, timed data collections can be set up which send automated notifications to remind operators when it’s time to perform HACCP, CCP, and other critical quality and safety checks. Operators can stay focused on production, without having to watch the clock or worry about missing a check. Plant supervisors also get alerts if a data collection is missed—no matter where they are working—so they can keep everyone on top of compliance.

Auditing just became that much easier

Auditing is already a time-consuming and resource-intensive process, adding another layer of stress and complexity to the already complex nature of food production. Those that rely on paper records and spreadsheets usually struggle to piece together and produce auditor-requested information. Failed audits can have major consequences for organisations, which is why they must be carried out perfectly every time.

When quality records and other compliance documentation are digitised, they become quickly accessible via the cloud. Data from specific timeframes can be easily pulled and reports now take just minutes to complete – for regulatory, third-party certification, or internal audits—rather than the days or weeks it would typically take following a complicated trail of paper.

Improve traceability and mitigate recall response

Recalls are another big source of stress for food manufacturers. After all, food quality or safety incidents that result in a recall not only hurt profits and brand reputation but also put the health and lives of consumers at risk. Fortunately, recalls can be mitigated or avoided through better traceability.

With the ability to trace raw ingredient lot codes through the manufacturing process and supply chain, and centralising that data within a singular cloud repository, manufacturers can create an overall timeline between incoming ingredients and outgoing products. This information is critical for preventing and responding to product recalls. If a safety issue is found within a specific ingredient lot, manufacturers can quickly identify output lots where those ingredients were used, prevent those finished lots from being released, or in the worst-case scenario, remove those lots from store shelves in a swift, targeted recall.

A new digital age

It’s clear to see that the industry at large is heading towards a new digital age. Food manufacturers shouldn’t wait to take the first steps, and cloud-based quality can get them on the right path. While any big change comes with hesitancy, a tactical approach can help ease any fears.

Some manufacturers have started with small-scale projects, deploying the cloud-based quality solution to monitor a single process or production line. Leadership teams can see how quality in the cloud benefits everyone at all levels of their organisation—and then deploy the solution on a wider scale. It is a great way to successfully introduce new digital technology and lay the foundation for future transformation.

A leading independent training provider is celebrating winning its largest apprenticeship contract in years after signing a major deal with Lander Tubular Products.

In-Comm Training, which operates three state-of-the-art technical academies across the Black Country and Shropshire, has become the strategic training partner for the supplier of precision engineered metallic and plastic manipulated pipe assemblies for the automotive, commercial vehicle and off-highway sectors.

Forty Level 2 apprentices in Lean Manufacturing Operations will be recruited over the next six months in a bid to develop a future talent pool that can help the manufacturer meet a rapidly growing order book.

(l-r) Paul Hodgetts (In-Comm Training) with Anita Davenport-Brooks (Lander Tubular Products)The new relationship will cover all recruitment and selection, advice on tapping into funding, induction process and delivery of training, with In-Comm trainers and assessors set to be permanently based at Lander Tubular Products’ internal academy at its Woodgate Business Park factory in Birmingham.

“This is a major milestone for our business, and we’re delighted that another high-profile industrial specialist has chosen to adopt our employer-led approach to apprenticeships and training in general,” explained Paul Hodgetts, Business Development Manager at In-Comm Training.

“The tender process was over a three-month period, involved six providers and numerous visits to each other’s locations. We were able to listen, understand exactly what the firm needed and then put together a flexible learning package that obviously appealed to the management team here.”

He continued: “Everything kicks off in September with a cohort of 15, then this is followed a month later with 10 more apprentices and the final 15 need to be in place by December. So, the message for young people and mature learners looking for a career change is simple – there’s the potential for high quality jobs with a world class automotive supplier, get in touch!”

With over 140 year’s history, Lander Tubular Products is a leading manufacturer of precision engineered metallic and plastic manipulated tubular products for the automotive, off-highway, and industrial sectors.

The company, which has three manufacturing sites in the UK and a further two production facilities in the USA, has a long history of delivering award-winning apprenticeship programmes.

Its product range covers multiple applications for the transfer of fluids or air, and tubular structural products for a broad range of major OEM and tier one customers.

Growing its own staff has always been a priority and this new contract marks the next phase of its workforce development, with pathways being created so that individuals can work all the way towards Technical Apprenticeships, a Degree in Engineering and Manufacturing and upskilling opportunities in continuous improvement, quality and leadership & management.

Anita Davenport-Brooks, Group HR Manager, added her support: “We’ve known about In-Comm for some time and were really impressed with the way they took the time to listen and tailor the approach to suit exactly what we need.

“The course will give every apprentice core manufacturing skills, as well as developing softer ones and encouraging the right behaviours to fit our culture. All the training will be completed at our factory, which will give us great flexibility when balancing shopfloor demand.

“I’m also keen to look at how we can work together to shape new Apprenticeship qualifications that are currently missing in industry. One example, is early discussions about creating a Level 3 Technical Operator course that could be the next step for our apprentices.”

She concluded: “Vocational learning is so important for us and, next year, the plan is to recruit up to 100 apprentices. Working with In-Comm Training will save over £200,000 on recruitment costs alone in 2022 and that does not take into account the bottom line benefits our learners will deliver to our three businesses across the Midlands.

“Several of our senior team and middle managers all started with an apprenticeship and are now critical to our future success.”

Lander Tubular Products, which was recently named as the number one company in the Top 50 SME Apprentice Employers Rankings by the National Apprenticeship Service, will also tap into other services offered by In-Comm Training.

This includes upskilling courses, health and safety consultancy and lobbying, with Anita already taking her place on the training provider’s new Skills Steering Group.

For further information, please visit www.in-comm.co.uk/www.lander.co.uk

Brenntag, the global market leader in chemicals and ingredients distribution, has become the exclusive distributor of Tolsa’s Functional Additives Business in the United States and Canada.

The product portfolio includes ADINS® Flame Retardancy, ADINS® Clean, ADINS® Protection and can be utilized in the Coatings & Construction, Polymers, Rubber, and Wire and Cable industries.

“We are excited to announce the expansion of our relationship with the Functional Additives division of Tolsa in North America,” stated Stephen Regular, Senior Director, Industry Market Management, Material Science, Brenntag North America.  “This unique chemistry, combined with both Tolsa and Brenntag’s technical support teams will enhance our already extensive portfolio and further solidify our position as the preferred chemical distributor for our customers.”

ADINS® is a patented technology based on natural silicates that provides new functionalities to materials and reinforces specific properties in organic and inorganic systems.

• ADINS® Flame Retardancy, synergist additives for Halogen and Halogen-Free systems, can be combined with the main polymeric systems including thermoplastics and thermosets, boosting the performance of Flame Retardants.  Some of the benefits include reduction of flame propagation, smoke suppression, and reduction of the heat release.
• ADINS® Clean, photocatalytic additives, is used for self-cleaning and decontamination functionalities. It is designed for paints, coatings, and cementitious systems.
• ADINS® Protection, antimicrobial additives, brings viricide, bactericide, algicide and fungicide protection to plastics, paint and coatings, textiles, and mortars.

“Tolsa Functional Additives is committed to empowering the best distribution partners globally, to all of our customers, in all markets of the world,” said Ms. Almudena Vidal Bea, Functional Additives Business Unit Director at Tolsa. “Based on our ongoing success of working with Brenntag in other regions in the world, this agreement confirms our commitment to our North American customers and partners, to ensure mutual value for all stakeholders.”

About Tolsa:
Tolsa has one of the most extensive and differentiated range of special clays worldwide, offering a broad range of additives and industrial products that provide high added value and improve the performance and efficiency of materials. Tolsa focuses on intelligent production that is modern, efficient, precise, flexible, punctual, safe, and respectful of the environment. Each process is subjected to stringent quality controls and the company is certified under ISO 9000 and ISO 14000. Tolsa has a production capacity of more than 1,2 million tons, and its factories are located near mining operations, or in port areas near end users. Further information at https://www.tolsa.com

About Brenntag:

Brenntag is the global market leader in chemicals and ingredients distribution. The company holds a central role in connecting customers and suppliers of the chemical industry. Headquartered in Essen, Germany, Brenntag has more than 17,000 employees worldwide and operates a network of about 700 sites in 78 countries. In 2021, Brenntag generated sales of around 14.4 billion EUR. The two global divisions, Brenntag Essentials and Brenntag Specialties, provide a full-line portfolio of industrial and specialty chemicals and ingredients as well as tailor-made application, marketing and supply chain solutions, technical and formulation support, comprehensive regulatory know-how, and digital solutions for a wide range of industries. In the field of sustainability, Brenntag pursues specific goals and is committed to sustainable solutions in its own sector and the industries served. Brenntag shares have been listed at the Frankfurt Stock Exchange since 2010, initially in the MDAX and since September 2021 in the DAX. In addition, the Brenntag SE shares are listed in the DAX 50 ESG and DAX ESG Target. For more information, visit www.brenntag.com.

Stora Enso and Northvolt are joining forces to create sustainable batteries using lignin-based hard carbon produced with renewable wood from the Nordic forests. The aim is to develop the world’s first industrialised battery featuring anode sourced entirely from European raw materials, lowering both the carbon footprint and the cost.

The companies have entered into a Joint Development Agreement to create a sustainable battery featuring anode produced from renewable raw materials sourced sustainably and locally in the Nordic countries.

“The joint battery development with Northvolt marks a step on our journey to serve the fast-growing battery market with renewable anode materials made from trees. Our lignin-based hard carbon, Lignode® by Stora Enso, will secure the strategic European supply of anode raw material, serving the sustainable battery needs for applications from mobility to stationary energy storage,” says Johanna Hagelberg, Executive Vice President for Biomaterials at Stora Enso.

Both companies bring key components, competence, and expertise to the battery partnership. Stora Enso will provide its lignin-based anode material Lignode, originating from sustainably managed forests, while Northvolt will drive cell design, production process development and scale-up of the technology.

“With this partnership, we are exploring a new source of sustainable raw material and expanding the European battery value chain, while also developing a less expensive battery chemistry. It is an exciting demonstration of how our pursuit of a sustainable battery industry goes hand-in-hand with creating a positive impact both on society and cost,” says Emma Nehrenheim, Chief Environmental Officer at Northvolt. 

Lignin is a plant-derived polymer found in the cell walls of dry-land plants. Trees are composed of 20–30% of lignin, where it acts as a natural and strong binder. It is one of the biggest renewable sources of carbon anywhere.

Stora Enso’s pilot plant for bio-based carbon materials is located at the Group’s Sunila production site in Finland, where lignin has been industrially produced since 2015. The annual lignin production capacity is 50,000 tonnes, making Stora Enso the largest kraft lignin producer in the world. The Group is also evaluating its first industrial production of Lignode at the Sunila site through a feasibility study.

Northvolt is a European supplier of sustainable, high-quality battery cells and systems. Founded in 2016 to enable the European transition to a decarbonized future, the company has made swift progress on its mission to deliver the world’s greenest lithium-ion battery with a minimal CO2 footprint and has grown to over 3,000 people from over 100 different nationalities. Northvolt has to date secured more than $55 billion worth of contracts from key customers, including BMW, Fluence, Scania, Volkswagen, Volvo Cars and Polestar, to support its plans, which include establishing recycling capabilities to enable 50 percent of all its raw material requirements to be sourced from recycled batteries by 2030.

Part of the global bioeconomy, Stora Enso is a leading provider of renewable products in packaging, biomaterials, wooden construction and paper, and one of the largest private forest owners in the world. We believe that everything that is made from fossil-based materials today can be made from a tree tomorrow. Stora Enso has approximately 22,000 employees and our sales in 2021 were EUR 10.2 billion. Stora Enso shares are listed on Nasdaq Helsinki Oy (STEAV, STERV) and Nasdaq Stockholm AB (STE A, STE R). In addition, the shares are traded in the USA as ADRs (SEOAY). www.storaenso.com

~ Can correct motor management cut costs in food and beverage production ~

With growing pressure on the food industry’s profit margins, companies must look to reduce manufacturing costs wherever possible. The food industry is incredibly energy intensive, accounting for around 30 per cent of global energy consumption and as a result, improving efficiency offers an opportunity to reduce costs. Here, Marek Lukaszczyk, European and Middle East marketing manager at the global manufacturer of electric motors, drives and gearboxes, WEG, explains how energy efficient motors and variable speed drives (VSDs) can help.

Increasing pressure is being placed on food and beverage companies to minimise wastage and improve resource use. Costs of raw materials, energy and labour are rising, while consumer demand for low prices increases, leading to intense competition and strict pricing pressure from retailers. Consequently, it is becoming increasingly difficult to maintain decent margins.

The food and beverage industry is also highly dependent on energy supply. Fluctuations in price and availability have the potential to cause major supply chain disruption — particularly due to price rises for carbon dioxide. Therefore, making food and drink production facilities as energy efficient as possible is essential to build a more resilient, futureproof business.

It makes sense, then, that many food manufacturers are looking for ways to improve the efficiency of their production. In fact, according to energy experts Centrica Solutions, 45 per cent of sustainable businesses are transforming energy data into actionable improvements.

Many of the most energy consuming processes in the food and beverage industry involve electric motors. Milling and centrifuging during sugar processing, grinding in flour production or even chilling frozen food products, are all driven by electric motors, and that’s just for starters.

Managing existing motors

The first step to improving energy efficiency in food manufacturing is taking stock of the status of existing motors. Food production relies on motors to power a whole host of processes, from conveyors and mixers to fans, pumps and refrigerators. However, many of the motors used in these applications could be oversized. Motors in applications like fans and pumps traditionally run at a partial load, using a valve, brake or throttle. However, this means that motors could be working harder than necessary, and by using mechanical speed control energy is wasted.

By choosing a motor of the appropriate size, or connecting a variable speed drive (VSD), food manufacturers can ensure motors are consuming only the necessary energy to power their equipment. VSDs enable motors to be run at a partial load more efficiently, as they directly control a motor’s speed and torque — the motor can be controlled to match demand, resulting in high energy efficiency even at different speeds.

Invest for long-term gains

It's also important to consider the age and condition of motors within a production facility. Older motors may have been rewound numerous times within their lifecycle. Whilst motors can be rewound to their original efficiency levels, in many cases this is not achieved.

Plus, older motors that require rewinding are often significantly less energy efficient than the latest models, thanks to years of technical advancements. In fact, thanks to pressure on governments to meet environmental targets, all new electric motors in the EU and the UK must now meet stringent energy efficiency regulations, depending on motor type and application. For example, as of July 2021 all new three-phase motors, the kind typically used in many food and drink applications, must meet IE3 standards.

It can often be the case that choosing to rewind a motor, rather than purchase a new one, offers a short-term cost benefit, but will result in manufacturers paying significantly more in the long run due to higher energy consumption. In fact, the energy cost to run an electric motor over ten years is at least 30 times the original purchase price, meaning new, energy efficient motors may quickly provide a return on the initial investment.

Replacing oversized ageing motors with new, correctly sized ones in line with IE3 or IE4 efficiency standards, represents significant energy savings for food manufacturers, particularly when used in combination with a VSD. But, how can facility managers know when existing motors need replacing?

Smart sensors for motor monitoring

The retrofitting of smart sensors to existing motors allows plant managers access to real-time, continuous data on motor performance. These sensors can monitor parameters such as vibration or temperature and alert engineers of any deviation from optimal performance.

WEG’s Motor Scan® solution consists of a sensor, easily attached to the motor fin, which communicates data to the cloud and enables analysis through WEG’s fleet management products. WEG Motor Specialist relies on machine learning and artificial intelligence (AI) to diagnose, monitor and indicate the need for predictive maintenance in electric motors.

WEG Motor Scan autonomously sends alerts when motors are running sub-optimally, enabling engineers to take steps to either repair or replace the motor in question. This avoids energy wastage and unexpected downtime — especially important in the food and beverage industry where the uncontrolled shutdown of a mixer or chiller can result in the loss of entire product batches.

By implementing strategies to gain additional insight into motor efficiency, ensuring motors are the right size for the application, and replacing ageing models with new energy efficient motors, food and beverage manufacturers can make significant energy savings. A more efficient plant brings with it improved profit margins, increased resilience and agility, and enhanced environmental credentials. With benefits such as these, taking steps to improve energy performance of motors in food production is an obvious choice.

For more information on energy efficient motors and drives for the food and beverage industry, go to www.weg.net

About WEG: Founded in 1961, WEG is a global manufacturer of electrical and mechanical equipment for industrial sectors across all continents. With manufacturing units in 12 countries and present in more than 135 countries, the company has more than 33,000 employees worldwide with net revenue of over R$17.47 billion in 2020.

Offering energy efficient solutions across all sectors including water, steel, pulp and paper, oil and gas, mining, among many others, WEG is constantly developing solutions to meet the major trends in energy efficiency, renewable energy, sustainability and electric mobility.  For more information, visit www.weg.net

Brazil’s industrial waste specialist Renova Group has advanced its alternative fuel capabilities, in a state-of-the-art collaboration with industrial shredder manufacturer UNTHA Iberica.

The family-owned business has commissioned a single-step RDF (refuse-derived fuel) production line, enabling it to transform waste into a renewable energy source, using only one shredding machine. A UNTHA XR30000C waste shredder now lies at the heart of the plant, producing a homogenous 50mm fuel for the cement industry.

Renova Group is no stranger to the reuse, recycling and recovery of commercial and industrial ‘waste’. The business has been collecting and treating varied materials – including metals, textiles, plastics, rubber and wood – for 36 years, and has five industrial sites throughout the country.

But passionate about investing in cutting-edge technology to advance Brazil’s waste handling capabilities – while minimising the environmental and fiscal impact of the process – Renova Group’s CEO is always looking for continuous improvement.

Aware of UNTHA Iberica’s growing profile in the complex Waste to the Energy market, the team conducted business trips to Europe to see exactly what the technology is capable of. UNTHA Iberica demonstrated the XR’s performance handling a number of different input materials to produce an on-specification RDF.

Impressed with the productivity of the machine – not to mention its low operating costs – Renova Group made the switch to UNTHA Iberica.

“We quickly realised that the UNTHA XR would increase our RDF production capacity and give us more process flexibility because the robust machine can handle a number of very difficult materials that prove too tough for most other shredders,” commented Renova Group’s CEO Eduardo Pirani.

“But we also knew that the profitability of our operation would be further improved because the UNTHA XR is so efficient. Consuming up to 75% less energy than diesel hydraulic equivalent shredders, the fuel savings are vast. The machine is also very easy to maintain, with little downtime, meaning general ongoing running costs are very affordable. In fact, our operating costs have already fallen by 40%.

“All of this with such a small footprint, given a single shredder is all you need. It’s very impressive!”

The XR is currently processing 15 tonnes of material per hour, to suit Renova Group’s requirements.

“Everything about this plant, has been designed with Renova Group in mind,” continued Eduardo. “Yes, the XR is very popular worldwide, but UNTHA Iberica took their time to carefully understand our requirements and configure the shredder to suit our exact requirements.

“The machine is now up and running but this is proving to be a fantastic ongoing partnership – our operators work well with UNTHA Iberica’s customer service experts, ensuring our shredder is always in optimum running condition, and we have quick and easy access to spare and wear parts when we need them. All of these factors matter when investing in shredding technology, and UNTHA Iberica tick all the boxes.”

Pfannenberg do Brazil provides local technical and commercial, product manufacturing to support global customers in Brazil and throughout LATAM

For 10 years Pfannenberg do Brazil has provided support to Global Manufacturers based in Brazil that rely on Pfannenberg’s thermal management and signalling solutions to keep their plants up and running.

Regional Director - Americas, Earl Rogalski remarked: "We have achieved this milestone through the hard work and dedication of our colleagues, our focus on customer service and the excellence that exists throughout our entire organization. We continue to focus our local efforts while leveraging our global resources to ensure we provide the most effective solutions for our customers in Brazil.”

Local efforts include

• Local Technical Support
• Commercial, Product Manufacturing
• Inventory Management Support
• Service and Repair

Managing Director – Brazil, Michel Leis remarked: “We have a dedicated team supporting all of our Brazilian partners.  It is great to be part of a global company that focuses on our local needs here in Brazil.

About Pfannenberg

Established in 1954 by Otto Pfannenberg in Hamburg, Germany, Pfannenberg, Inc. is recognized as a leading global manufacturer of thermal management technologies within the Electro-technology Industry. In 1958 we invented the Filterfan^®, which continues to be recognized worldwide as a leading product to help manage the temperature in electrical enclosures. Our business philosophy: Protecting Man, Machine, and the Environment.

One of the UK’s leading printed circuit board manufacturers has become the latest company to join the Manufacturing Assembly Network (MAN), as it pledges to record a £30m turnover by 2026.

Stevenage-based electronics specialist Nemco posted an £11m turnover figure in the last financial year and believes its involvement in the unique collective of sub-contract manufacturers and an engineering design agency will play a crucial role in helping it reach the ambitious target over the next four years.

MAN, which employs more than 1750 people across 13 different factories, offers every engineering discipline imaginable, including aluminium casting, automation and control systems, forging, high-volume pressings, plastic injection moulding, precision machining, tube manipulation and welded assemblies.

Attracting Nemco to the group is seen as a huge coup, with the printed circuit board assembly experts boasting a diverse client base touching many different sectors, including aerospace, defence, industrial and medical.

“We’re thrilled to be a part of MAN, for the simple reason that the group boasts like-minded businesses who are progressive, ambitious and looking to grow,” explained David Duric, Sales & Marketing Director at Nemco.

“There is no competition within the group, so there is a great culture of transparency and best practice sharing that can only be good for our business. Importantly, we also offer new solutions that complement the core capabilities of other members in the Manufacturing Assembly Network.

“It has been a tough time in the manufacturing sector due to the global pandemic and its after-effects. We effectively lost a year somewhere and although there was a slight dip in the order book during the initial pandemic, we remained strong and diversified to weather the storm."

He continued: “Thankfully we recovered because we acted quickly. We planned ahead and we kept on investing in new machinery and strengthening our purchasing department to offset the rising costs of raw materials. This combined approach has seen us emerge in a position of strength.”

Nemco, which was formed in 1985 by Dave Pearce and currently employs 122 people at its 60,000 sq ft Wedgwood Way facility, has identified significant opportunities in the renewable energy and EV sectors and is planning to make significant inroads in the months and years ahead.

It has also recruited two dedicated business development managers for the first time, who will spearhead a strengthened sales team, tasked with focusing on new opportunities and working with MAN to explore joint opportunities.

David added: “We are equally adept at providing finished PCB solutions or assisting our clients with their own processes.

“In some cases, they work up their designs and pass them on to us to create. We make up to 24,000 in one week for one client in the medical sector, so our work is extremely varied.”

MAN, which works together to win new contracts and share best practices, comprises Alucast, Barkley Plastics, Brandauer, Grove Design, James Lister & Sons, Kimbermills International, PP Control & Automation and Muller Holdings.

The group has secured a string of contracts across automotive, electronics, medical and renewables following the easing of lockdown.