The High-Speed Forge: Revolutionizing the Industry of Custom Rolled Rings Acquiring custom, high-quality components can mean the difference between staying on schedule and costly delays in the intricate and high-stakes industry. Among these critical components, seamless rolled rings are the unsung heroes found in the innovatively designed turbines of aircraft engines and the hulking machinery of mining and oil rigs. Each is custom-crafted to exacting specifications for a genuinely fit-for-purpose product. The critical nature of these rings has traditionally come with a trade-off—a long and unpredictable lead time in the manufacturing process until now. The innovative approach that industry leader All Metals & Forge Group has taken is changing the narrative. By establishing a unique position in the market, they offer not just any rings but tailor-made, high-quality, seamless forged rolled rings, ready in incredibly efficient timeframes that once seemed unattainable. Meeting the Industrious Demand The importance of seamless rolled rings in the mechanical heart of various industries isn’t just significant; it’s indispensable. Traditionally, obtaining these rings has been mired in the constraints of efficiency and speed, often taking up to a year from the point of order to delivery. The impact of such delays can be profound, from halting production lines in automotive manufacturing to compromising the safety of critical systems in aerospace. Speed Meets Precision The forging industry has seen a significant transformation in production timelines, cutting down what used to take months to just eight weeks. This shift towards quicker production is not about rushing or overlooking details; it’s about expert coordination and skillful use of advanced manufacturing technologies. All Metals & Forge Group has tackled these challenges innovatively. By leveraging state-of-the-art production capabilities and forming strategic partnerships, the company now delivers products in a fraction of the time compared to industry norms, typically within eight to ten weeks. This achievement reflects their dedication to efficient manufacturing, emphasizing speed, reliability, and precision – qualities crucial in industries with stringent standards to uphold. The Art and Science of Customization Seamless rolled rings are ingenuity materialized, a result of the unique science of forging that melds metal into its perfect form. Beyond their functionality, attention to detail and customizability set specialized forgers like All Metals & Forge Group apart. With the facility to craft rings across a spectrum of materials—from the robustness of titanium for aerospace to the resistance of stainless steel for petroleum industries—the process is a symphony of art and science, culminating in a product that is as durable as it is precise. Cost and Waste Efficiency Forging has long been admired for its durability. A lesser-known but crucial benefit is the reduction of waste and material costs. Crafting seamless components without welds results in sturdier final pieces and significantly reduces the material and energy needed. In an era increasingly conscious of carbon footprints and sustainability, forging stands out as a lasting and effective method. Taking customization to a deeper level, All Metals & Forge Group enhances the efficiency of their rings not only in design but also in manufacturing. By focusing on near-net shaping, they create rings with smoother surface finishes, minimizing the need for extensive post-forging machining. This speeds up delivery and enhances the operational efficiency of their clients’ machining processes, providing a strategic edge in the competitive industry landscape. Industrial Efficiency with Advanced Forging Techniques The emergence of efficient ring forgers like All Metals & Forge Group highlights a shift towards sustainability in the industry. Their forging process minimizes waste and cuts down on manufacturing costs, showing a commitment to environmental consciousness. By prioritizing reducing lead times, they promote eco-friendly practices for a future where precision meets sustainability. The trajectory of the forging industry is being rewritten by All Metals & Forge Group. Their blueprint for innovation caters to the very foundation of industry, where time, precision, and reliability are instrumental. They portend the future where high-quality, custom components do not mean persistent lead times but swift and assured efficiency. It is a model not just of speed but of sustainable strength, and it resonates a message in the industry, urging a comprehensive reevaluation of what efficient production truly means. With the mantle of this industrial revolution firmly on their shoulders, the path ahead for All Metals & Forge Group and, by extension, those industries they service is one of promising potential. This revolution in ring forging isn’t just about material strength and building solid relationships. Through fostering client relations and strategic partnerships, All Metals & Forge Group isn’t just a custom ring provider but a catalyst for transforming industry norms. Their approach emphasizes collaboration over competition, shaping the company as a progressive client partner. For more information: Contact All Metals & Forge, LLC at 75 Lane Road, NJ 07004; (973) 276-5000; Canada 416-363-2244, toll-free (800) 600-9290; fax (973) 276-5050 Read Full Article

Ensuring a Seamless Launch and Consistent Performance of Animal Feed Conveyors The journey towards a successful and sustained performance of animal feed conveyors requires careful planning and execution. This article discusses the importance of conducting detailed research before purchase and the vital roles of expert-supervised installation and commissioning in ensuring smooth operation. To handle delicate animal feed products or powders effectively, manufacturers and processors conduct thorough research before investing in a tubular drag cable conveyor that aligns with their requirements in terms of function and cost. Post-purchase, expert assembly, and testing of the conveyor are crucial for ensuring seamless production startup and sustained performance. The Crucial Role of Supervised Installation in Conveyor Reliability The inception phase of integrating a new animal feed conveyor system into your operation lays the groundwork for its longevity and efficiency. The supervised installation is a critical component, often overlooked but pivotal for harnessing the equipment’s full potential. This section will unravel how expert oversight during installation mitigates the risks of mechanical failures and ensures the system aligns perfectly with the operational workflow, setting a solid foundation for optimal performance. Specialized animal feed conveyors require a deep understanding for correct installation, a task often beyond the capabilities of third-party contractors. Engaging the OEM’s team of skilled technicians for the installation process can prevent costly mistakes, delays, and potential harm. Leveraging the OEM’s experienced technicians with in-depthknowledge of the conveyors they design can help avert costly errors. Ensuring Proper Installation for a Seamless Startup Ensure every component is correctly installed to achieve a seamless startup of your animal feed conveyor system. This critical phase affects the conveyor’s immediate functionality, long-term reliability, and efficiency by exploring essential steps and considerations for proper installation. From aligning mechanical parts to electrical connections, every detail matters in paving the way for a smooth transition from installation to operation, minimizing the risk of downtime, and maximizing productivity right from the start. A successful installation process involves meticulous assembly, accurate positioning of hangers, and thorough cleaning to prevent premature wear and misalignment. Supervised installation not only guarantees a flawless setup but also preserves the standard warranty provided by the manufacturer. Leveraging Expert Commissioning for Reliable Production Following the supervised installation, the next critical milestone in the life cycle of an animal feed conveyor is the expert commissioning process. This phase ensures the system operates strictly as intended and reaches its full potential. This section will explore the importance of a thorough commissioning process by skilled professionals. Their expertise facilitates a smooth transition into production and sets the stage for reliable and efficient operations, safeguarding against future disruptions and optimizing overall system performance. Commissioning is an essential step following installation, involving inspection, testing, and fine-tuning of the conveyor system. The commissioning process on-site prepares the conveyor for total production and identifies any immediately correctable issues to maintain the startup schedule. This process enhances efficiency and reliability, with the technician providing a comprehensive report documenting all findings. The Importance of Long-Term Support and Maintenance Beyond the critical stages of professional installation and commissioning lies the ongoing commitment to the conveyor system’s health through diligent long-term support and maintenance. This section highlights the indispensable role of regular maintenance routines and reliable support from the manufacturer or a specialized service team. Ensuring your animal feed conveyor system operates at peak efficiency prolongs its lifespan and prevents unexpected downtimes, maintaining continuous production flow and safeguarding your investment over time. Beyond the initial installation and commissioning stages, long-term support and maintenance play pivotal roles in maintaining the conveyor’s performance. Regular system inspections and training aim to extend the conveyor’s lifespan and prevent any unnecessary downtime. Maximizing Efficiency and Reliability through Animal Feed Conveyors Achieving success with your startup and maintaining optimal performance for animal feed conveyors requires meticulous research, expert installation, and consistent maintenance. Enhance the longevity and reliability of your conveyor system by adhering to these guidelines. Collaborating with a reputable OEM or specialized service team can offer valuable guidance and assistance to enhance efficiency and productivity, leading to operational success. With careful planning, execution, and ongoing support, animal feed conveyors can be invaluable assets in the agricultural sector. Making informed investments in the right conveyor system is essential to ensure proper installation, commissioning, and continuous support for reliable operation. Remember that an animal feed conveyor isn’t merely a piece of equipment; it forms the cornerstone of your production process. Ensure its durability and maintenance for enduring productivity in the long term! For more information, visit Cablevey Conveyors or call toll-free at +1 (800) 247-3344. Read Full Article

Revolutionizing Food Processor Wastewater Treatment with Automatic Scraper Strainers Effective wastewater treatment is paramount in any industry. The food processing sector comes with its own unique set of challenges. The problem for wastewater treatment is that no fluid processing or filtration system remains static. Treatment conditions continually change due to variable factors such as pressure, particle size, solids loading and even the presence of sticky biologicals. Fortunately, a separation technology designed to tolerate variability – automatic scraper strainers – can be used when reliable, economic, low-maintenance water treatment is necessary. This blog post delves into how automatic scraper strainers can revolutionize the process when they are used after clarifiers and before further processing. Understanding Food Processor Wastewater Treatment The food processor industry generates a significant amount of wastewater characterized by organic matter, suspended solids, grease, fats, and chemical residues. The need for efficient wastewater treatment cannot be overstated. The Food Processor Industry and Wastewater From meat packing to vegetable processing, every segment of the food processor industry contributes to wastewater. Understanding these sectors and the characteristics of their wastewater is key to effective treatment. Challenges in Wastewater Treatment Food processor wastewater treatment is often plagued by several challenges: Accumulation of solids and debris Algae growth and fouling Clogging of equipment and pipelines Presence of contaminants   Explore the role of automatic scraper strainers in tackling these unique wastewater treatment challenges within the food processing industry. Delve into the characteristics of wastewater the food processor industry generates and the need for efficient treatment strategies. Automatic Scraper Strainers: The Game Changer Learn about the groundbreaking functionality of these innovative devices and their profound impact on enhancing treatment efficiency. Modern automatic scraper strainers like Acme’s are meticulously engineered to withstand unexpected challenges. Acme’s motorized unit is purpose-built to eliminate both large and small suspended solids from wastewater consistently. This is achieved through a meticulously designed spring-loaded blade and brush system, expertly managed by a fully automated control system. Tackling Accumulation and Algae Growth Explore the methods utilized by automatic scraper strainers to address issues related to accumulation and algae growth effectively. When it comes to wastewater, conventional automatic backwash strainers face a unique challenge posed by adhesive biologicals such as algae. These biologicals not only foster the presence of other contaminants like scum, grease, sludge, and foam, but they also gradually diminish the strainer’s usable open area. Over time, conventional automatic backwash strainers will lose effectiveness and require cleaning to restore their proper function. Biofouling Prevention Strategies Uncover the benefits of automatic scraper strainers in combating biofouling, a prevalent issue in wastewater treatment. By employing scraper brushes, these strainers efficiently eliminate particulates and solids from wedge-wire slots, averting clogs and fouling. This approach guarantees comprehensive cleaning and proves particularly effective in mitigating organic matter biofouling. The Synergistic Impact of Scraper Strainers on Food Processor Wastewater Treatment Companies must adapt to changing wastewater treatment conditions influenced by production and seasonal variations. To meet compliance requirements and safeguard downstream equipment consistently, it is crucial to employ flexible and reliable technology. Automatic scraper strainers are purpose-built for these challenges, gracefully handling surprises and variability while minimizing maintenance needs. Discover more for a comprehensive exploration of these topics as we delve deeper into the revolutionizing role of automatic scraper strainers in food processor wastewater treatment! For more information, visit Acme Engineering Products Inc. Read Full Article

Warehouse Safety Unleashed: Safeguard with Expert Strategies Warehouse safety should never be taken lightly. Insufficient safety measures can lead to accidents, operational downtime, product losses, property damages, and potential legal actions. This guide provides a comprehensive approach to increasing warehouse safety, protecting your bottom line, and ensuring the well-being of your employees. 1. Define and Protect Walkways Around Racking One of the easiest ways to prevent accidents in the warehouse is by clearly defining and protecting walkways and work areas around racking. This can be achieved through lines painted on the floor or visual and physical barriers such as guardrails. These measures ensure that pedestrians and vehicles have defined routes, keeping them separate and reducing the risk of collisions. 2. Equip Your Warehouse with Guardrail and Safety Gates Guardrails and safety gates serve as an excellent line of defense for warehouse equipment. Not only do they protect the equipment, but they also safeguard mezzanines/platforms, conveyor systems, machinery, electrical panels, and building features. This ensures easy access and flexibility of use for warehouse operators while maintaining a high level of safety. 3. Shield Your Rack from Forklift Damage High-traffic areas within the warehouse are often prone to accidents, particularly those involving forklifts. Using guardrails can go a long way in protecting your rack from forklift damage, thus saving you from costly repairs and potential downtime. 4. Prevent Rack Columns from Structural Damage Rack columns are a critical part of the warehouse infrastructure. Protecting them from structural damage is crucial for maintaining the integrity of your inventory. Freestanding steel rack protectors can effectively safeguard the rack columns’ base plate and lower leg. 5. Deflect Impact to the Rack with Snap-On Solid Steel Protectors Snap-on solid steel protectors are a cost-effective way to deflect and absorb impact to the rack face. They easily attach to the rack’s teardrop holes, providing extra protection for your inventory. 6. Install Rub Rails in Narrow Aisles Rub rails are especially useful in narrow aisles or high-traffic areas with a higher risk of damage. They protect the end-of-rack aisles and prevent the column from twisting when hit. 7. Protect Your Inventory from Falls and Fires Using pallet load stop beams can prevent pallets of product from being accidentally pushed off the back of a rack during loading or unloading. By keeping pallets in the proper position with sufficient clearance, pallet load stop beams also facilitate better fire suppression from overhead sprinklers in the event of a warehouse fire. 8. Secure Non-Standard Load Sizes with Load Supports For non-standard load sizes, consider using load supports to help keep inventory from falling between the rack beams that support the product. 9. Keep Loose Products from Falling Off Racks Protect loose products from falling off racks by installing barriers or netting. This not only enhances safety but also prevents inventory loss. 10. Train Employees to Prevent Accidents and Inspect Racking Regularly Last, training employees to prevent accidents and regularly inspect racking is crucial. Safety training can help warehouse operators identify potential hazards and take preventive measures. Implementing Effective Warehouse Safety Measures The safety and efficiency of a warehouse are significantly improved by properly managing non-standard load sizes, preventing loose items from falling off racks, and regularly training employees to prevent accidents and conduct inspections. By adhering to these principles and incorporating tools like load supports and rack decking options, warehouses can minimize inventory loss and create a safer environment for employees. Hence, such strategies must be implemented not just as an afterthought but as integral aspects of warehouse management. Enhancing warehouse safety does not have to be a daunting task. By implementing these easy tips, warehouse operators can significantly reduce accidents, protect their inventory, and safeguard their bottom line. For more information, call Steel King at (800) 826-0203 or visit them online at www.steelking.com. Read Full Article

Boosting Dairy Production: The Power of Bagged Silage The Potential of Bagged Silage for Enhanced Dairy Production In the dairy farming industry, the quality of feed directly impacts milk production and cow health. One innovative approach that has revolutionized dairy farming is bagged silage. This article explores the significance of bagged silage and its potential to optimize dairy production. It delves into the benefits of utilizing this method, shedding light on how it can enhance overall productivity in the dairy industry. The Role of Quality Feed in Dairy Production The Equation: Quality Feed Equals High Milk Production The quality of feed plays a crucial role in maximizing dairy production. Good feed improves cow health, leading to increased milk production. On the other hand, poor feed results in reduced milk production and increased health issues among cows. Therefore, dairy farmers must prioritize providing their cattle with high-quality feed. Total Mixed Ration (TMR) and Silage: The Perfect Combo Total Mixed Ration (TMR) and silage are vital components of cow feed. TMR ensures cows get a balanced diet, while silage provides necessary nutrients. Silage, in particular, is an excellent source of energy for cows. It is made by fermenting corn or grass and storing. Silage Bagging: A Revolutionary Approach to Feed Preservation Silage Bagging vs. Traditional Methods Silage bagging presents a more efficient and cost-effective solution compared to conventional methods. It reduces feed loss and maintains nutrient retention, promoting better milk production. Conventional methods, such as bunkers, pits, or piles, can result in significant nutrient loss due to exposure to air and weather elements. The Benefits of Using Silage Bags Silage bags present numerous benefits for dairy farmers. They are available in different sizes, making them suitable for small and large dairy farms. With their airtight nature improving prolonged storage, they ensure feed quality is maintained for an extended period. Silage bags provide superior protection against spoilage, ensuring the feed’s overall quality is maintained. As a result, this leads to enhanced cow health and increased milk production. Boosting Dairy Production with Nutrient-Rich Feed Dairy farmers can ensure their cows receive nutrient-rich feed through bagged silage, enhancing milk production and overall herd health. Silage bags can provide cows with a consistent and balanced diet year-round with proper storage and handling. This helps maintain milk production even during drought or other challenging weather conditions. The Magic of Silage Bagging Equipment Advancements in Silage Bagging Equipment The Versa ID900N bagger are prime examples of advancements in silage bagging equipment. These machines can produce bags up to 12 feet in diameter that are 500 feet long. The Key Role of Packing Pressure Packing pressure is essential in silage bagging. It helps create an airtight environment, preventing spoilage and mold growth. The Versa ID900N bagger have high packing pressure capabilities, ensuring optimal feed preservation. Embracing Silage Bagging as an Industry Best Practice The Benefits of Silage Bagging: A Recap Silage bagging offers numerous benefits, including higher nutrient retention per acre, increased milk production, enhanced cow health, reduced veterinary costs, and improved efficiency. These benefits make it an industry best practice for dairy farmers. Adoption of Silage Bagging: A Win for Dairy Farmers Adoption of silage bagging is a cost-effective and sustainable practice that promotes the health and productivity of dairy cows, thereby boosting dairy production. It also allows farmers to optimize their land use and reduce feed waste. As the dairy industry continues to evolve, embracing innovative practices like silage bagging is crucial for staying ahead. With its numerous benefits, it’s no wonder that silage bagging has become a popular choice among dairy farmers worldwide! Exploring the Future of Silage Bagging in Dairy Farming Bagged silage is a game-changer in the dairy farming industry. Its adoption not only increases milk production but also enhances overall farm profitability. As we move towards more sustainable and efficient farming practices, bagged silage stands out as an industry best practice worth embracing. For more information, call (800) 837-7288 or visit versacorporation.com. Read Full Article

Revolutionizing Drug Discovery: Surface Modification of Well Plates Well plates have become indispensable in research, drug discovery, and diagnostic testing. However, these well plates often require advanced surface modification and functional coatings for high-resolution testing to improve the adhesion, proliferation, and signal-to-noise ratio. This surface modification enhances the interaction between cells, biomolecules, and drug compounds. In recent years, there has been a growing interest in utilizing well plate surface modification techniques to revolutionize the field of drug discovery. Applications in Drug Discovery Surface modification of well plates has vast implications for drug discovery applications. These modifications allow for better control and optimization of cell culture conditions, resulting in more accurate and reliable data. These modifications can also enhance the interaction between cells and drugs, making it easier to identify potential drug candidates. Screening and Lead Optimization Surface modification techniques have enabled the development of highly sensitive well plates that can detect even low concentrations of compounds. This has revolutionized the process of screening and lead optimization, allowing for faster and more efficient identification of potential drugs. Surface Modification Techniques Surface modification techniques involve altering a material’s surface’s chemical or physical properties without changing its bulk properties. These modifications can be achieved through various methods, such as chemical treatments, plasma surface modification, or coating with functional materials. In the case of well plates, these surface modifications are essential to improve the performance of cells and biomolecules for drug discovery applications. Chemical Treatments Chemical treatments involve altering the surface properties of a material by exposing it to specific chemicals. For well plates, examples include treatment with oxygen plasma to increase hydrophilicity or coating with polylysine to promote cell adhesion. These chemical treatments can be precise and targeted, allowing for specific modifications of well plate surfaces. Plasma Surface Modification Plasma surface modification involves exposing a material’s surface to an ionized gas, which causes changes in the surface properties. This method is often used to improve the surface energy of well plates, making them more compatible with cell adhesion and growth. Plasma treatment can also introduce functional groups onto the surface, allowing for specific targeting of biomolecules. Coating with Functional Materials Coating well plates with functional materials is another popular surface modification technique. These coatings can be made from various materials, such as polymers, proteins, or peptides. These coatings can improve cell adhesion, proliferation, and differentiation on the surface of well plates. Understanding the Limitations of Pre-coated Well Plates While pre-coated well plates could meet the needs of more straightforward research requirements, they are often inadequate for innovative research and development in drug discovery and diagnostic test development. This is primarily due to their high costs and lack of customization. Researchers and scientists engaged in cutting-edge R&D projects require more flexibility and control over experimental conditions, which can be achieved through customizable, well plates tailored to their needs. By utilizing such customized well plates, researchers can optimize their experiments and achieve more accurate and reliable results, ultimately accelerating progress in biotechnology and healthcare. The increasing demand for advanced surface modification techniques in the biotechnology and healthcare industries has led to the emergence of contract services for well plate surface modification. These service providers offer customizable surface modifications tailored to specific research requirements, saving researchers time, effort, and costs. Collaborating with these service providers allows for faster development and commercialization of new drugs, contributing to the overall growth of research and development purposes. Unlocking the Power of Plasma Treatment Well Plates Plasma treatment offers a unique solution to overcome various challenges associated with well plates. By utilizing energetic species such as electrons, ions, radicals, neutrals, and radiations, plasma treatment effectively cleans, activates, chemically grafts, and deposits a wide range of chemistries onto well plate coatings. Well plates are extensively used in research and diagnostic labs to conduct multiple tests simultaneously. Typically composed of polystyrene, these plates provide stability and optical clarity. However, untreated synthetic polymers used in well plates tend to be hydrophobic, lacking adequate cell binding sites. To address this issue, plasma treatments are employed to modify the surface of well plates, creating a hydrophilic surface that enhances cell adhesion and facilitates biomolecule attachment. This surface treatment also improves the wetting of wells, promotes cell proliferation, reduces the amount of serum or reagent necessary for testing, and minimizes the risk of contamination. Advantages of Plasma Treatment The benefits of plasma treatment include: Enhanced adhesion promotion and conjugation of bioactive molecules. Enhanced wetting of wells. Facilitated cell proliferation without clumping. Reduced risk of contamination. Improved binding sites. The Role of Contract Service Providers Companies such as PVA TePla, a leading provider of contract services, specialize in offering the technical expertise required for applying functional coatings. By engaging these service providers, businesses can expedite their time to market and avoid the need for costly in-house investments in equipment and expertise. The emergence of contract services offering customized functional coatings has proven to be a highly effective and efficient alternative for manufacturers. For example, labware manufacturers can now acquire affordable, uncoated labware and entrust it to experts like PVA TePla for plasma treatment. This ensures optimal results and allows manufacturers to focus on their core competencies while benefiting from the specialized knowledge and capabilities of service providers like PVA TePla. With this approach, manufacturers can achieve superior quality, cost-effectiveness, and faster turnaround times in bringing their products to market. The Benefits of Outsourcing to a Contract Services Provider For researchers and manufacturers looking to reduce the costs of coated well plates while improving research quality and diagnostic test resolution, outsourcing to a qualified contract services provider can be an optimal solution. By partnering with a contract services provider, researchers and manufacturers can benefit from: Lower costs through economies of scale. Specialized expertise in surface modification techniques and equipment. Streamlined processes for coating customization. Faster time to market. Improved research quality and diagnostic test resolution. Transitioning from R&D to Production A contract services provider with extensive experience can offer priceless insights and guidance when transitioning from R&D to production. They possess deep

Silent No More: The Truth About Dual-Pane Windows and Noise Reduction Are you having trouble sleeping because of noise pollution from outside? Are you tired of the constant honking of cars and noisy neighbors? You may have considered replacing your windows with dual-pane versions to create a quieter home. However, it’s important to note that dual-pane windows may not provide the solution you had anticipated. Discover why dual pane windows fail to block out noise effectively and explore how advanced “soundproof” windows provide homeowners a superior alternative. Delve into the science of noise reduction and uncover the innovative technology behind these cutting-edge soundproof windows. High-Tech “Soundproof” Windows for Quick Installation, Noise Reduction, and Energy Efficiency Thanks to technological advances in window manufacturing, we now have access to high-tech soundproof windows that can reduce outside noise by up to 95%. These state-of-the-art windows utilize laminated glass and a larger air space, providing better sound insulation and vibration control capabilities than traditional dual pane windows. Additionally, by reducing noise pollution, these windows can increase energy efficiency in the heating-cooling portion of energy bills by 15-30%. Not only do these windows block out disruptive noise, but they also come with a much simpler installation process. With quick and easy installation, you can quickly enjoy peace of mind from living in a quieter home. These “soundproof” windows are the perfect solution for anyone looking to reduce outside noise and ensure energy efficiency in their home. Investing in quality soundproofing will provide you with years of peaceful enjoyment, all at an affordable price. So don’t wait any longer – make your home a haven of tranquility today! The Science Behind How Soundproof Windows Work for Noise Reduction Soundproof windows work on a principle called sound wave interference. When two sound waves meet at a certain angle, they cancel each other out and reduce the overall noise level. This is achieved through multiple layers of glass and specialized acoustic films, creating an airspace that disrupts the sound waves as they travel through the window. In addition to this advanced technology, soundproof windows have thicker frames and seals that help block out any remaining noise. This combination of materials and design dramatically reduces outside noise, providing homeowners with a peaceful and quiet living space. The manufacturing process of soundproof windows ensures a better seal, eliminating any gaps that could allow exterior noises to enter. Homeowners can benefit from increased energy efficiency along with reduced outside noise. The quick and hassle-free installation approach makes them an attractive option for anyone upgrading their current windows. Why Dual-Pane Windows Do Not Effectively Stop Noise Dual pane windows were designed to insulate homes against heat and cold, not noise. The glass panes are merely separated by a small gap filled with air or gas, making them inadequate in reducing outside noise. Additionally, the drum effect of the glass panes causes vibrations that defeat noise reduction. Dual pane replacement windows may provide some minimal noise reduction, ranging from 0% to 20%. This minimal reduction is not worth the investment and can leave homeowners frustrated and still needing a peaceful home environment. Moreover, installing dual-pane windows can be costly and disrupt your daily routine. How Much Noise Do Double-Pane Windows Reduce? True soundproof windows deliver exceptional noise reduction by utilizing advanced technology. These cutting-edge windows incorporate laminated glass and an optimal air space, effectively blocking up to 95% of external noise. The laminate provides an additional barrier against sound, combining two layers of glass with a thin polyvinyl butyral resin. This ingenious design enhances the windows’ soundproofing capabilities, creating a formidable barrier that effectively hinders the penetration of sound waves and ensures maximum noise reduction. In addition to providing soundproofing, windows with reinforced glass offer enhanced security and safety benefits. The presence of laminated glass makes it challenging for intruders to break in, ensuring homeowners have peace of mind and added protection. The durable construction of laminated glass also makes it resistant to impact and severe weather conditions, guaranteeing long-lasting performance.  Investing in cutting-edge soundproof windows allows you to create a serene environment in your home or office without worrying about external noise. These innovative products provide superior sound insulation and extra security for your property. You can trust that our soundproof windows will protect you from outside disturbances while affording you the quiet you deserve. Soundproof Windows, Inc. – Engineering Secondary Soundproofing Windows Soundproof Windows, Inc. has revolutionized the field of soundproofing windows with its innovative approach. By designing secondary windows that can be installed behind existing ones, they have elevated the concept of noise reduction to new heights. The secondary window has a layer of laminated glass, an air space, and impeccable seals that leave no room for gaps. Not only does this solution provide homeowners with the benefits of soundproof windows, but it also offers a cost-effective alternative to window replacement. Moreover, these windows are particularly well-suited for historical buildings where altering the primary windows is not viable. Soundproofing Windows for Preserving Historical Buildings and Windows In addition to the functionality of their soundproof windows, Soundproof Windows, Inc. is also committed to preserving and protecting historical buildings. They specialize in creating custom solutions for these unique environments, allowing them to maintain the history built into each window and wall. The company has employed a variety of projects that not only ensure noise reduction but also preserve the look and feel of older structures. Their work adds value to communities by ensuring historic sites remain intact while providing modern conveniences such as sound insulation. The team at Soundproof Windows, Inc. has extensive experience in creating the ideal window and wall insulation solutions for a variety of different projects. They specialize in designing secondary windows installed over existing windows and walls to reduce noise levels drastically while preserving aesthetics with custom frames to match surrounding trim. For added sound reduction benefits, laminated glass can be included as part of the installation process and create an air space between the two panes, which seals out outside noise. This

Revolutionizing Corporate Month-End Close with Streamlined Software Solutions Closing the books on financial statements at the end of each month is a critical responsibility for any accounting team. The month-end close process often brings stress and headaches for CFOs and controllers, involving meticulous sub-ledger closing activities, general ledger journal entries, and constant monitoring of deadlines. However, this monthly task can become less overwhelming with the right software in place, like PowerClose by InfoMoksha. PowerClose software is specifically designed to streamline the entire enterprise’s start-to-end financial accounting and sub-ledger processes. Automating and optimizing tasks ensures accurate and time-efficient month-end closing. Discover the benefits of PowerClose software and how it can revolutionize accounting operations, automate the close cycle, and improve overall efficiency. Benefits of PowerClose Software PowerClose software offers several benefits, including time and resource savings, improved accuracy, and streamlined work processes. By automating the sub-ledger and general ledger accounting activities, PowerClose ensures accurate and consistent financial reporting. The software offers the following benefits: Automated month-end close cycle Streamlined sub-ledger and general ledger processes Improved accuracy of financial data Reduced data entry time and cost savings Enhanced visibility into accounting activities PowerClose software helps companies reduce manual errors, decrease the amount of time needed to complete tasks and improve overall efficiency. With its easy-to-use interface, PowerClose can quickly become essential to any business’s accounting operations. Streamlining and Automating the Close Cycle PowerClose software integrates fully with the company’s ERP system, streamlining and automating all close-cycle tasks. PowerClose software has a workflow-based platform to orchestrate and oversee the entire closing process, ensuring all close-cycle tasks are executed and reported correctly. With this software, managing month-end closing tasks that require accounting sub-ledgers completion becomes more comfortable and less time-consuming. Automated Close Feature PowerClose software has a unique feature for automated closing. Users can automate the closing of a period upon the completion of specific activities, such as closing purchasing and inventory periods upon confirmation of final shipments. Automated functions streamline processes, saving users precious time by minimizing manual input required for balance checks. This efficiency ultimately reduces employee working hours while maintaining accuracy and effectiveness. Dashboard for Task Monitoring PowerClose provides a comprehensive dashboard that offers a birds-eye view of crucial tasks, eliminating the need for manual tracking and follow-up during time-consuming financial close activities. With this feature, users can effortlessly monitor all activities in one centralized location, reducing the need to check deadlines constantly. This not only enhances accuracy but also streamlines accounting operations seamlessly. Integration and Improved Corporate Performance By integrating the PowerClose software into a company’s operations with HUBIC, businesses can unlock a range of benefits. These include a streamlined and automated close cycle, improved corporate performance, enhanced work processes, reduced errors, and optimized accounting operations. HUBIC provides a comprehensive API solution that effectively manages, tracks, and reports global intercompany transactions’ financial and tax implications. The program boasts an intuitive and user-friendly interface, enhancing the accounting team’s overall efficiency. Simplify Corporate Month-End Close with Streamlined Software Closing the books on a monthly basis can be a time-consuming endeavor that demands precision, consistency, and multitasking across departments. InfoMoksha’s PowerClose software provides a solution by automating and streamlining the closing cycle. This not only saves time but also enhances the overall efficiency of the accounting team. By reducing errors, improving accounting operations, and ensuring accurate financial reporting, the software proves to be a valuable asset. Its dashboard offers a comprehensive overview of essential tasks, including a unique feature for automated closing. By integrating PowerClose software, companies can achieve better corporate performance through streamlined processes. With accurate and timely month-end closing, valuable resources are freed up for other critical business operations. Read Full Article

Optimizing Electronic Component Inventory Management Post-Pandemic The COVID-19 pandemic has caused unprecedented disruptions in the supply chain for electronic components. One critical issue that has arisen is the surplus inventory of electronic components. This challenge has been exacerbated by the constantly evolving market trends and the surging demand for industries such as the banknote printing machine market. Manufacturers have been grappling with soaring prices and extended lead times, resulting in stockpiling and multiple orders from various sources. As we navigate through these challenging times, many manufacturers find themselves burdened with excess inventory, while others are actively seeking ways to fortify their supply chain against future disruptions. Classic Components, a leading independent distributor based in Torrance, CA, offers valuable insights into effectively managing and optimizing inventory in the post-pandemic era. Tackling the Challenge of Excess Inventory The COVID-19 pandemic led to an unprecedented disruption in supply chains, resulting in a surplus of electronic components in various sectors. Companies like Classic Components have been grappling with this issue, trying to find effective ways to reduce their excess inventory post-pandemic. Excess inventory is a common issue post-pandemic. Many manufacturers, facing huge lead times, ordered multiple times from various sources, leading to an overstock of parts. Independent distributors like Classic Components can help by leveraging their extensive databases and strategic relationships to find alternative sources. They can also help liquidate dead stock through arrangements such as brokering deals between parties, selling surplus inventory on consignment, or purchasing it outright for resale later. Revisiting EOQ and Reorder Point Models One way to optimize inventory management is through the Economic Order Quantity (EOQ) and reorder point models. These models can be beneficial when dealing with multiple suppliers and varying lead times. EOQ is a model that determines the ideal order quantity a company should purchase to minimize its inventory costs. On the other hand, the reorder point is the level of inventory that triggers an action to replenish that particular inventory stock. Both these models can be optimized to manage inventory levels and reduce excess stock effectively. The Economic Order Quantity (EOQ) model is a crucial tool in inventory management. It helps determine the optimal order quantity that minimizes total inventory costs, including holding and ordering costs. However, optimizing EOQ and reorder point models can be challenging when dealing with multiple suppliers and lead times. Calculating Optimal Reorder Points and Safety Stock The optimal reorder point is the inventory level at which a new order should be placed to replenish stock before it runs out. On the other hand, safety stock is extra inventory kept on hand to guard against variability in demand or supply. To calculate these, consider factors like demand rate, lead time, and service level desired. A higher service level leads to more safety stock, while longer lead times increase the reorder point and safety stock. Reducing Inventory Carrying Costs with Long Lead Times Long lead times can lead to higher inventory carrying costs as you have to hold more stock to meet demand. To reduce these costs, consider strategies like supplier development to shorten lead times, demand forecasting to better predict needs, and inventory reduction techniques like Just-in-Time inventory. These strategies can help you balance the costs of holding inventory against the cost of stockouts and customer dissatisfaction. With the right strategies, you can manage your inventory levels more effectively and reduce your carrying costs. By understanding inventory control principles, businesses can better manage their supply chain processes and stock levels. They must consider factors like demand, order frequency, and lead times to do this. With an understanding of inventory control principles, businesses can design and implement effective strategies to reduce their carrying costs and better serve customers. Enterprise Resource Planning Systems Additionally, utilizing technology solutions like Enterprise Resource Planning (ERP) systems can help companies automate processes related to inventory management and increase efficiency. ERP systems provide a comprehensive view across all aspects of a business’s inventory management, allowing them to streamline processes and increase visibility into their supply chain. Ultimately, this helps businesses improve overall efficiency and reduce costs associated with carrying inventory. Real-Time Tracking Product Tracking Technology solutions like RFID tracking can also help businesses manage inventory more effectively. Using Radio Frequency Identification (RFID) tags, companies can track products in real-time and ensure they are managed more accurately and efficiently. These tags can be embedded in items or attached to them, which allows businesses to track their inventory more precisely. This provides an accurate tracking system for businesses, helping them better manage their supply chain. Monitoring, Analyzing, and Calculating Inventory Pricing Strategies Calculating inventory cost and markup is vital for pricing strategies and profitability analysis. Costs can be calculated using FIFO, Last-In-First-Out (LIFO), or average cost method. Markup is typically a percentage added to the inventory cost to determine the selling price. Monitoring Expiry Date Monitoring and tracking expiry dates of perishable items is essential for maintaining product quality and reducing wastage. Consider utilizing automated systems for monitoring and alerting staff when expiration dates are near. This can save resources, time, and money in the long run. Updating Inventory Records Setting up an efficient inventory control system helps maintain accurate records. Take the time to regularly update inventory records of all products, including incoming and outgoing stock. This will help to avoid unnecessary orders and costly losses due to inaccurate counts. Effective Electronic Component Inventory Management Management in a post-pandemic world requires strategic planning and utilizing models like EOQ. Independent distributors like Classic Components offer solutions for excess inventory and provide valuable insights into navigating supply chain disruptions. By leveraging these services, organizations can increase profitability by optimizing inventory levels while ensuring smooth operations. In addition to EOQ, organizations should implement best practices in electronic component inventory management. This includes maintaining accurate stock records, forecasting demand, setting realistic reorder points based on sales data, creating purchase order schedules, and monitoring supplier performance. Regular inventory audits ensure correct storage and tracking of all parts. Effective component inventory management involves tracking stock levels, forecasting needs, setting realistic reorder points based on

The Mobile Cable Positioning Device (CPD): A Cost-Effective and Eco-Friendly Solution to Connect Ships to Shoreside Electricity Ships are a significant source of air pollution, accounting for about 2.5% of global greenhouse gas emissions. To reduce this pollution, many ports have implemented shore power systems that allow ships to connect to shoreside electricity while in port, reducing their use of onboard generators. However, connecting ships to these systems can be costly and time-consuming. This is where the Mobile Cable Positioning Device (CPD) comes in. What is the Mobile Cable Positioning Device (CPD)? The Mobile CPD is a cost-effective solution that Watts Marine developed that simplifies connecting ships to shoreside power. It is a mobile manlift on a turret that rotates 360 degrees and can be strategically positioned to accommodate vessels of different sizes and configurations. The device can be used with any shoreside electric power system and can be moved to support different ships quickly. Mobile CPD: Eco-Friendly and Game-Changing The Mobile CPD is powered by a battery, making it more eco-friendly than diesel-powered generators. Additionally, it is a game-changer for ports as it facilitates the connection to shoreside electrical power for various ships. Once the connection is made, the ship’s systems run on shore electricity, reducing fuel emissions while in port. This benefits the environment and reduces costs for both the port and ship. Cost-Effective Solution The Mobile CPD is a cost-effective solution compared to traditional shore power systems. It eliminates the need for costly infrastructure, such as fixed pedestals or substations, and does not require ship modifications. This makes it an attractive option for ports looking to implement shore power systems without significant investments. The device also has a lower operational cost, not requiring maintenance or fuel costs. Easy to Use and Versatile The Mobile CPD is designed to be user-friendly, with straightforward controls and easy maneuverability. It can also be used for other tasks, such as ship maintenance and repair, making it a versatile tool for port operations. Its mobility allows for efficient use of space and can accommodate multiple ships simultaneously, further increasing its cost-effectiveness. As more ports aim to reduce their carbon footprint and comply with environmental regulations, the demand for shore power systems will continue to grow. The Mobile CPD offers a practical and sustainable solution that meets these objectives while being cost-effective and versatile. Its potential to revolutionize port operations makes it a crucial tool in the maritime industry’s efforts towards a cleaner and greener future. Watts Marine: Experts in Shore Power Systems Watts Marine has installed shore power systems at various ports worldwide. This covers every step of the shore power process, from regulatory advising to system operation and maintenance. Their expertise in shore power systems ensures that the Mobile CPD is seamlessly integrated into existing systems and effectively connects ships to shore power. Case Study: Success at a Major Port Watts Marine recently installed their Mobile CPD at a major port, significantly reducing diesel emissions. The Mobile CPD simplified the process of connecting ships to shore power and accommodates vessels of various sizes and configurations, reducing operational costs and environmental impact. The port has seen a significant decrease in emissions, making it more environmentally friendly and cost-effective. Successful Experts in Shore Power Systems The Mobile Cable Positioning Device (CPD) is a cost-effective, eco-friendly solution that Watts Marine developed that simplifies connecting ships to shore power. It is powered by a battery and can be used with any shoreside electric power system. The device is a game-changer for ports and will facilitate the connection to shoreside electrical power for various ships. Watts Marine’s expertise in shore power systems ensures that the Mobile CPD is seamlessly integrated into existing systems and effectively connects ships to shore power. Read Full Article

LithiBatt: A Paradigm Shift in Battery Recycling In today’s technological era, sustainable solutions are more critical than ever. One company championing this cause is BCA Industries’s trailblazing division, LithiBatt. LithiBatt is set to redefine the landscape of lithium-ion (Li-ion) and lithium-iron phosphate (LiFePO4) battery recycling. Unleashing the Power of Turnkey Systems LithiBatt’s cornerstone lies in its comprehensive recycling systems. These systems offer a multitude of processing options, ranging from material shredding to generating battery-grade precursor cathode active material (pCAM) and “black mass.” The latter is a treasure trove of valuable metals that can be recovered, reused, and reintroduced into the economic cycle. LithiBatt can handle a broad scope of battery types and chemistries through these turnkey systems while still delivering world-class recycling performance. A Sustainable Solution Apart from its technological prowess, LithiBatt’s core values revolve around sustainability. The company envisions a greener future where batteries are recycled efficiently rather than ending up in landfills or incinerators. Through its turnkey systems, LithiBatt reduces the carbon footprint caused by traditional recycling methods while promoting a circular economy. Strategic Partnerships: The Road to Success LithiBatt isn’t just working on its own; it’s forging powerful alliances with industry titans. By integrating complementary recycling technologies amplifies the value of recoverable materials and minimizes operational costs. Strategic partnerships with companies like Redwood Materials, a leading battery recycling company, enable LithiBatt to leverage its technological and operational expertise. Through these alliances, the company can scale up its operations, expand its reach, and achieve greater sustainability goals. The company’s trustworthiness and reliability are evident from its collaborations. It’s installing systems for the world’s largest battery recycling company and the biggest EV manufacturer, a testament to its credibility and reputation. Such strategic partnerships boost LithiBatt’s reach and position it as an industry leader in the battery recycling domain. Joining Forces with Green Li-ion LithiBatt’s partnership with Green Li-ion, a pioneer in lithium-ion battery recycling technology, is another feather in its cap. This alliance underscores LithiBatt’s mission to recycle all metals in black mass materials and repurpose them for new batteries. Green Li-ion’s cutting-edge hydrometallurgical process helps recover cobalt, nickel, and copper from spent batteries. Combined with LithiBatt’s thermal processing technology, it can achieve a recovery rate of up to 99% for these critical metals. Pioneering the Future with U.S. Department of Energy Grant LithiBatt, a pioneering company in the energy sector, has recently embarked on an exciting journey by submitting an application for a highly sought-after grant from the U.S. Department of Energy (DOE). The primary objective behind this bold move is to establish a cutting-edge and state-of-the-art demonstration facility that will revolutionize the recycling process. This remarkable facility will showcase LithiBatt’s groundbreaking recycling technology and serve as a beacon of innovation and sustainability. By opening its doors to manufacturers and recyclers, this facility will give them a unique opportunity to witness the recycling process firsthand. The visitors will have access to real-time recycling data, empowering them to make well-informed decisions before investing in the equipment. With this visionary initiative, LithiBatt aims to advance the recycling industry and foster a more sustainable future. The demonstration facility will demonstrate the efficacy of their recycling process and inspire and drive the adoption of similar sustainable practices across the industry. A Revolutionary Transformation in Battery Recycling LithiBatt, a pioneering company in sustainable innovation, is leading the charge in shaping the future of lithium-ion battery recycling. Through its groundbreaking efforts, LithiBatt is poised to set a new benchmark in the industry, revolutionizing the way batteries are recycled and establishing a more sustainable and circular economy. LithiBatt is making significant strides toward a greener, more sustainable future by prioritizing environmental stewardship and technological advancements. Read Full Article

How One-Stop Shops like PTR Group Maximize Value for OEMs through Strategic Acquisitions In the intricate ecosystem of Original Equipment Manufacturers (OEMs), procuring specialized parts from multiple suppliers can prove to be a resource-intensive, costly, and time-consuming endeavor. Discover more about utilizing OEMs in the market through the insightful case study on Wheatland Tubes, which has shown OEMs with strategic acquisitions and streamlined services. This is where one-stop shops like PTR Group come into play, offering consolidated services that facilitate parts sourcing and adapt seamlessly as product needs evolve. The Strategic Role of One-Stop Shops in the OEM Industry PTR Group has strategically positioned itself as a one-stop shop for OEMs by extending its services from design to manufacturing across diverse materials. This single-source parts model eliminates the need for OEMs to engage with multiple vendors, leading to significant time and cost savings. Moreover, it allows for better collaboration in parts design and engineering, fostering manufacturing synergies. Innovative Manufacturing Solutions As OEMs continue to look for innovative solutions to increase efficiency, PTR Group is investing in advanced manufacturing processes like pulse plasma nitriding that enhance surface treatment, wear resistance, fatigue strength, and material performance. The move also aligns with the shift towards lifetime readability of tags, signs, and markers and reducing the excess inventory of electronic components post-pandemic. The company’s commitment to eco-friendly solutions is evident from its foray into electric boilers for boiler room modernization. They are equipped to advise customers on all aspects of the transition process, from deciding on boiler type and size to a comprehensive list of considerations such as staffing and maintenance. Broadening Parts Portfolio through Concentric Acquisitions PTR Group has adopted a concentric acquisition strategy to broaden its parts portfolio. They have acquired companies offering complementary parts manufacturing, allowing them to provide a range of value-added parts and services beyond just manufacturing. This strategic move has led to the diversification of their product range, which now includes valve protection, compressed gas cylinder components, and fittings. OEM Industry Case Study: Wheatland Tube Wheatland Tube, a division of Zekelman Industries, exemplifies the benefits of PTR Group’s one-stop-shop model. Wheatland Tube has streamlined its operations and improved efficiency by sourcing steel couplings for multiple markets from a single vendor. PTR Group has also met Wheatland Tube’s stringent quality and strategic acquisition standards while allowing them to customize components and reduce lead times. PTR Group’s Strategic Companies Specialize in Innovation PTR Group excels with its wide range of companies under its umbrella, showcasing its strength in diversity. For instance, ACCI Industries and PTR Tool and Plastics provide expertise in different materials and finishes. Premier Hydraulics, another company under the PTR Group, specializes in custom hydraulic components and assemblies. These companies collectively offer services like CNC machining, stamping, deep drawing, laser cutting, powder coating, and welded assemblies. Combining these services results in a fast development process, allowing customers to bring their products to market quickly and efficiently. This is why Wheatland Tube counts on PTR Group for product innovation. By leveraging the capabilities of all its companies, PTR Group helps Wheatland Tube stay ahead of the competition with high-quality parts delivered on time and at competitive prices. Embracing Eco-friendly Solutions and Innovative Manufacturing Processes PTR Group has revolutionized the parts supply chain for OEMs by adopting a one-stop-shop model. From design to manufacturing, they offer a seamless process that results in cost savings and increased efficiency. Through strategic acquisitions, they have managed to diversify their offerings and cater to the evolving needs of OEMs across different industries. For more information on PTR Group and their services, visit their website. Read Full Article

The Future of Aerospace Manufacturing: The Science of Diffusion Bonding Technology advancements enable innovative aerospace product creation. One breakthrough, diffusion bonding, joins dissimilar metals in manufacturing. Design engineers favor it for process control and compatibility. Explore diffusion bonding intricacies, applications, and its competitive edge when partnering with PVA TePla. Unlike traditional welding, diffusion bonding solidly intermixes metallic surfaces without melting. The result is a robust and ductile bond with minimal stress. It is ideal for high-strength, reliable applications at elevated temperatures. Potential Applications of Diffusion Bonding in Aerospace Manufacturing Diffusion bonding is gaining popularity in the aerospace industry for connecting different metals. It offers advantages like weight reduction and improved fuel efficiency. Bonding titanium to iron-nickel alloys, titanium alloys to stainless steel, or even aluminum to other metals is remarkable. However, a deep understanding of the interface and its impact on chemical and thermo-mechanical properties is crucial for harnessing diffusion bonding’s potential in aerospace. The Role of Expert Partners in the Industry Diffusion bonding offers a multitude of possibilities beyond simply joining dissimilar metals. One such exciting application is conformal cooling, where layers of sheet metal with intricate channel and microchannel structures are fused together. By implementing this process, cooling systems in aerospace can achieve enhanced efficiency through a more uniform distribution of cooling. Moreover, the utilization of this process in conformal cooling has the potential to reduce weight and cost, making it a compelling choice over traditional cooling systems. The Promising Influence of Diffusion Bonding One of the significant advances in diffusion bonding technology is the development of high vacuum hot presses. These presses allow for superior pressure control and rapid cooling systems, improving the bond, increasing yields, and significantly decreasing cycle time. These advances have made the process easier and more efficient, making it a more viable option for aerospace manufacturers. Nevertheless, it remains crucial to collaborate with industry experts like PVA TePla to fine-tune the process for specific applications and unlock its full potential. This strategic partnership ensures optimization and maximizes the myriad benefits that can be achieved. Significance of Continuous Research and Advancements in the Aerospace Industry Diffusion bonding is an incredibly exciting and cutting-edge development in the aerospace industry. It holds immense potential for joining dissimilar metals and enhancing cooling systems. While the technology has made significant progress, it still requires the expertise of specialists to optimize the process for specific applications. By collaborating with renowned experts like PVA TePla, manufacturers in the aerospace industry can gain a significant competitive edge in part design and production ramp-up. As technology advances, we eagerly anticipate the new applications and groundbreaking innovations that will emerge from the fascinating science of diffusion bonding. Read Full Article

Unleashing the Power of Pulse Plasma Nitriding in the Aerospace Industry The aerospace industry demands high levels of precision and quality, necessitating advanced and reliable surface treatment processes. Surface finishing techniques must ensure resistance to wear, fatigue, and corrosion for parts that are put under strenuous loading conditions. Pulse plasma nitriding is a technique that offers aerospace manufacturers a solution to increase wear and corrosion resistance while enhancing material performance. Nitriding has been a go-to for aerospace surface treatment for years, but recent advancements in pulse plasma nitriding have taken this technique to a new level. We will explore pulse plasma nitriding’s advantages and how it improves aerospace surface treatment, wear resistance, fatigue, and material performance. The Mechanism of Pulse Plasma Nitriding and Boosting Aerospace Material Efficiency https://youtu.be/IWLlBXYOaIU Pulse plasma nitriding is an advanced type of nitriding that offers aerospace manufacturers several benefits over traditional nitriding techniques. The process injects nitrogen and hydrogen gases into a chamber, where a current discharge conducts a plasma and activates nitrogen molecules. These “formed” nitrogen ions diffuse into the metal’s surface, forming a hard nitride layer. Recent advancements have made the process more precise and controllable, resulting in a uniformly hardened case depth, preserving the component’s dimensions, and contributing to better fatigue performance. Advantages and Benefits for the Aerospace Industry Compared to traditional gas nitriding, pulse plasma nitriding offers more uniform case-hardening and increased processing speed when treating high-wear parts. The improved chamber design and construction dissipate heat more efficiently, ensuring all components receive uniform heating and hardening. This uniformity leads to high repeatability, better quality control, and consistent nitride layer thickness, reducing the likelihood of failure under high-stress loading conditions. Expanding the Application of Pulse Plasma Nitriding in the Industry Aerospace manufacturers that use high-alloy materials like titanium and stainless steel can benefit from these advanced surface treatment options. The process offers low-temperature case hardening and nitrocarburizing for rust and acid-resistant stainless steel, increasing wear resistance without compromising corrosion resistance. Additionally, high-temperature pulse plasma nitriding of components made of titanium or titanium alloys provides consistent hardening through precise temperature control. Furthermore, pulse plasma nitriding uses nitrogen and hydrogen, an environmentally friendly and non-toxic alternative to other gas nitriding techniques. This application can be integrated with machining processes, so locating the process in a separate room is unnecessary, increasing efficiency throughput. A Future-Ready Approach for Aerospace Manufacturing The advanced nature of pulse plasma nitriding provides aerospace manufacturers with substantial throughput optimization. These systems offer multiple heating and cooling zones through uniform temperature distribution, increasing chamber capacity. Manufacturers can benefit from greater uniformity of results, better-protected materials, and increased throughput, leading to significant savings in both cost and time. Pulse plasma nitriding systems are also a more energy-efficient solution for the aerospace industry, designed to minimize energy consumption. Additionally, another use can be for various alloys and materials that are not typically compatible with traditional heat treatment processes. This makes the process more versatile than conventional methods. As the aerospace industry evolves, there is an ever-growing need for innovative technologies to help manufacturers better manage their production operations. By leveraging pulse plasma nitriding processes, aerospace organizations can enhance their production operations by improving efficiency, quality, and cost. This technology provides significant advantages over traditional treatments, such as increased surface hardness and corrosion resistance. The process requires minimal energy consumption, which helps to reduce operating costs and maximize efficiency. This process also improves product consistency and repeatability due to its precise nature. As a result, manufacturers can create highly reliable parts that meet stringent industry standards. With the ability to produce stronger components with greater precision, aerospace companies can create top-tier products and deliver them to their customers ahead of schedule. Ultimately, pulse plasma nitriding gives aerospace organizations the tools to reach their production goals while maintaining environmental sustainability. Embracing Pulse Plasma Nitriding for the Global Aerospace Industry Pulse plasma nitriding enhances precision, control, and wear resistance for aerospace manufacturers. It outperforms traditional gas nitriding with improved uniformity, throughput, and cost savings. This environmentally friendly treatment seamlessly integrates with machining processes, making it ideal for the aerospace industry. Manufacturers can elevate component performance and ensure top quality by employing methods. Leading aerospace manufacturers embrace this solution for superior surface finishing, maintaining a competitive edge while boosting efficiency and reducing costs. 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NovaTech Striking the Perfect Power Balance in Smithville, TN The OrionLX Substation Automation Platform, developed by NovaTech, offers various advanced functionalities, including monitoring, control, visualization, and security, as seen in Smithville, TN. Its primary and secondary balancing schemes automatically regulate the power factor balance by switching capacitor banks, resulting in remarkable advantages for utility companies. This system reduces labor requirements for grid monitoring and ensures nearly full power factor compliance with the Transmission Network Operator, enhancing overall power system efficiency and stability. Perfect Power Balance in Smithville, TN The success story of a small utility in Smithville exemplifies the significance of investing in cutting-edge technologies to optimize power system balance while meeting strict grid compliance requirements. By implementing this comprehensive and effective power-balancing system, the utility not only improved its reliability and quality of electricity services but also catered to the demands of large industrial loads, which are often challenging for smaller utilities with limited SCADA systems. With minimized manual oversight and control, these advanced platforms offer unprecedented efficiency levels. In this article, we delve into the challenges small utilities face in maintaining this delicate balance and address their susceptibility to large industrial loads. We highlight the transformative impact of implementing an automated power system balance by exploring a captivating case study of a small municipal utility in Smithville, Tennessee. Witness the significant benefits of this implementation, showcasing the potential of advanced solutions to revolutionize power generation. NovaTech’s Advanced Cutting Edge Solutions Join us as we embark on an enlightening journey into power system balance. Discover how cutting-edge solutions are shaping the future of electricity utilization, unraveling intricate possibilities that lie ahead. Read the full article to explore a world where efficiency, reliability, and innovation converge. Read Full Article

Upcoming Trade Publication || StrikeHold® For Critical Law Enforcement Gun Maintenance StrikeHold® is set to unveil new information about its unique gun cleaner and lubricant in an upcoming trade publication. Proper gun maintenance is paramount for law enforcement officers who depend on firearms for their safety and the well-being of the public. While traditional solvents and oil-based lubricants might fall short, leaving guns vulnerable to corrosion and contamination, StrikeHold® offers a groundbreaking solution. Developed originally for the military, it’s now gaining traction among U.S. law enforcement agencies and revolutionizing firearm maintenance standards with its exceptional features. StrikeHold® Key Features Superior Protection: StrikeHold® is a unique gun cleaner and lubricant that offers unmatched protection against corrosion, carbon residue, and contaminants. Its application creates a hard finish that safeguards firearms in all weather conditions. Battle-Tested Performance: Developed for the U.S. military, StrikeHold® has been extensively tested on various weapons systems, from pistols to tanks. Its reliability and effectiveness have made it a trusted choice for demanding military operations. Testimonials from Law Enforcement: Sgt. Joe Whitehead from the Venice Police Department in Florida attests to the reduction in dry firearms and malfunctions due to oil issues after using StrikeHold®. Mike Jolly from the Highlands Police Department in North Carolina describes it as the best all-around weapon cleaner on the market for law enforcement. Wet Application and Fast Drying: StrikeHold® is applied while wet and forms a protective film upon drying. This shield-like film prevents carbon build-up, contaminants, and corrosion, ensuring optimal firearm performance. Cleaning Power: StrikeHold® acts as a powerful cleaner, removing firing residues, gum build-up, and foreign debris from weapon components. It keeps firearms in top condition, eliminating potential malfunctions. Friction Reduction: The synthetic-based additives in StrikeHold® act as microscopic ball-bearings, significantly reducing friction within the firearm’s moving parts. This results in improved accuracy, reliability, and smoother operation. Simplifying Firearm Maintenance: StrikeHold® addresses the time-consuming nature of gun maintenance, making it easier for law enforcement officers to prioritize regular cleanings. It streamlines the process while extending the lifespan of firearms. Future of Law Enforcement Gun Maintenance StrikeHold® has emerged as the future of law enforcement gun maintenance, offering unmatched protection, reliability, and ease of use. Law enforcement agencies across the United States are to be adopting this revolutionary product, recognizing its transformative impact on firearm performance. With its battle-tested heritage and glowing testimonials from officers, StrikeHold® is set to become a staple in law enforcement trade publications. For more information and to experience the benefits of StrikeHold®, contact StrikeHold Sales at 866-331-0572, email info@strikeholdsales.com, or visit Firearms – StrikeHold or StrikeHold on www.amazon.com. Empower your officers with the best in firearm maintenance—StrikeHold®. Read Full Article

Are You Getting the Full Health Benefits of Turmeric? Are You Getting the Full Health Benefits of Turmeric? A new approach to turmeric supplements provides the full spectrum of the superfood’s naturally occurring compounds Turmeric is the top-selling herb in U.S. natural food stores for good reason, and while it is great to add turmeric to your diet, the most reliable way to ensure a daily dose of turmeric is through a dietary supplement. However, many turmeric products on the market today are concentrated extracts of just one of its active constituents, curcumin, and three problems plague curcumin-only products. Fortunately, a new approach to turmeric supplements is resolving many of these issues while offering the whole range of the superfood’s naturally occurring compounds to maximize its health benefits. What is Turmeric? Turmeric, which gives Indian curry and American mustard their distinctive yellow colors, has been used in Chinese and Indian herbal medicines for thousands of years. Western medicine has increasingly acknowledged its effectiveness in helping to prevent or relieve a wide range of ailments without the noted side effects of many traditional drugs. Inflammation plays a role in many chronic health issues, from joint aches and pains to serious health problems. Turmeric contains a host of anti-inflammatory compounds, including curcumin, that fight inflammation at the molecular level. Because of curcumin’s chemical structure and stimulation of the body’s antioxidant enzymes, it can also neutralize harmful free radicals in the body that can damage DNA, proteins, cell membranes, and other organic structures. In reviewing 700 studies of turmeric, in fact, the ethnobotanist James Duke, PhD. concluded in a 2007 issue of Alternative & Complementary Therapies that turmeric appears to outperform many pharmaceuticals in its effects against several chronic, debilitating diseases with virtually no adverse side effects. Recent research confirms that turmeric extract supports brain health, emotional health, heart health and immune system health, as well as reducing joint and muscle aches and pains. This ancient food, properly extracted and concentrated, is one of the greatest “healthy aging” supplements ever found. Why full spectrum turmeric is critical First, turmeric’s activity relies on the whole range of its naturally occurring compounds, not just curcumin. Other beneficial compounds are discarded when curcumin is artificially inflated to make up 95% of a turmeric extract. Second, some of turmeric’s active components are fat-soluble and some are water-soluble. Yet most products focus solely on the fat-soluble components and neglect the water-soluble ones. Third, to make matters worse, curcumin is very poorly absorbed by the human body. Some people compensate with massive doses in hopes of absorbing a little, but that approach is imprecise and can cause stomach upset. Many methods have been used to improve curcumin bioavailability. However, they often use a high proportion of fillers – typically 70 to 90 percent – and thus contain low levels of actual curcumin and even lower levels of other beneficial constituents. To resolve these issues, supplement manufacturers are now releasing turmeric extract products that contain curcumin plus the full spectrum of turmeric’s naturally occurring compounds. As an example, Yerba Super Turmeric features Super Turmeric extract, the world’s most bioavailable, full spectrum turmeric extract. Developed by two doctors, Super Turmeric combines a fat-soluble extract with a water-soluble extract, so it delivers all the beneficial components of turmeric. This results in rapid absorption through the gut, for immediate relief, plus 24-hour activity in the bloodstream for round-the-clock support. While adding turmeric to one’s diet will only become more popular as its health promoting attributes become more widely recognized, those selecting supplements with the full spectrum of the superfood’s naturally occurring compounds may enjoy the most complete benefits. For more info, email yerba@yerbaprima.com; visit www.yerbaprima.com; or write to Yerba Prima Inc. at 740 Jefferson Ave., Ashland, OR 97520 USA.

Achieving Water Authority Compliance with Printing Wastewater Treatment Achieving Water Authority Compliance with Printing Wastewater Treatment Wastewater treatment systems help printers remain in compliance with EPA and local standards, while significantly reducing the cost of treatment, labor and disposal. The printing industry must meet EPA and local wastewater requirements for effluent, including those under the Clean Water Act. Failing to do so can result in severe fines that quickly escalate. Whether for books, magazines, specialty cards, corrugated paper, or packaging, the use/changeover of printing inks of assorted colors on various media is a source of considerable wastewater when the printing equipment must be cleaned and maintained. Invariably, the combined colors turn the wash water into an inky black wastewater. Printing ink usually consists of dyes, pigments, resins, binders, solvents and additives. Decorative metallic inks, often used in holiday cards, party plates or napkins, can also utilize heavy metals such as cobalt, iron, zinc and copper. Under the Clean Water Act alone, the EPA has identified 65 pollutants and classes of pollutants as “toxic pollutants,” of which 126 specific substances have been designated “priority” toxic pollutants. For the printing industry, this means installing a wastewater treatment system that effectively separate the contaminants from the water so it can be legally discharged. However, traditional wastewater treatment systems can be complex, often requiring multiple steps, a variety of chemicals and a considerable amount of labor. Even when the process is supposedly automated, too often technicians must still monitor the equipment in person. This usually requires oversight of mixing and separation, adding of chemicals, and other tasks required to keep the process moving. Even then, the water produced can still fall below mandated requirements. Although paying to have such wastewater hauled away is also an option, it is expensive. In contrast, it is much more cost effective to treat the wastewater at its source, so the treated effluent can be legally discharged and the resulting sludge passes a TCLP (Toxicity Characteristics Leaching Procedure) test and can be disposed of as non-hazardous waste in a local landfill. Fortunately, complying with EPA and local wastewater regulation has become much easier with a variety of more fully automated wastewater treatment systems. Such systems not only reliably meet regulatory wastewater requirements, but also significantly reduce the cost of treatment, labor and disposal when the proper Cleartreat® separating agents are also used. Cost-Effective, Automated Wastewater Treatment In contrast to labor-intensive multiple step processes, automated wastewater treatment can help to streamline production, usually with a one-step process, while lowering printing costs. An automated wastewater treatment system can eliminate the need to monitor equipment in person while complying with EPA and locally mandated requirements. Such automated systems separate suspended solids, emulsified oil and heavy metals, and encapsulate the contaminants, producing an easily de-waterable sludge in minutes. The water is typically separated using a de-watering table or bag filters before it is legally discharged. Other options for de-watering include using a filter press or rotary drum vacuum. The resulting solids are non-leachable and are considered non-hazardous, so it will pass all required testing. These systems are available as manual batch processors, semi-automatic, automatic and can provide a legally dischargeable effluent. A new, fully customized system is not always required. In many cases, it can be faster and more cost effective to add to or modify a manufacturer’s current wastewater treatment systems when this is feasible. However, because every waste stream is unique to its application, each wastewater treatment solution must be suited to or specifically tailored to the application. The first step in evaluating the potential cost savings and effectiveness of a new system is to sample the wastewater to determine its chemical make-up followed by a full review of local water authority requirements. The volume of wastewater that will be treated is also analyzed, to determine if a batch unit or flow-through system is required. Other considerations include the size restrictions so the system fits within the printer’s available footprint. An example of successful automated wastewater treatment involves one of the largest independent corrugated manufacturers, which processes over 8 million sq. ft. of corrugated packaging and displays per day. The corrugated manufacturer required more efficient treatment of wastewater that is generated from the washdown of its flexographic printing presses that use various inks in the manufacturing process. For this, the corrugated manufacturer turned to an EconoFlow fully automated wastewater system as well as Cleartreat separating agent from Sabo Industrial Corp., a New York-based manufacturer, distributor and integrator of industrial waste treatment equipment and solutions, including batch and fully automated systems, Cleartreat separating agents, bag filters, and accessories. The system included a high-volume flow-through mix unit, ground level feed hopper, bag filter housing for solids removal, self-indexing dewatering table, and final polishing vessels. Sensors ensure proper material flow and operation, and onscreen audio-visual alerts indicate if anything requires attention. However, instead of typical labor-intensive in-person monitoring of equipment, to correct a problem the mix chambers’ motors are controlled electronically by Human Machine Interface (HMI) and can be remotely adjusted, along with the mix motor speed, and powder feed by a Sabo Industrial technician. The industrial wastewater equipment provider can utilize the equipment’s integrated webcams as needed to view the mixing chambers for flocculant formation, floc structure, color and water clarity. Remote access also enables viewing alert conditions on the touchscreen and provides the ability to reset the machine, if needed. Separating Agents Despite all the advances in automating wastewater treatment equipment any such system requires effective separating agents which agglomerate with the solids in the wastewater so the solids can be safely and effectively separated out. Because of the importance of separating agents for wastewater treatment, Sabo Industrial uses a special type of bentonite clay in a line of wastewater treatment chemicals called ClearTreat. This line of wastewater treatment chemicals is formulated to break oil and water emulsion, provide heavy metals removal, and promote flocculation, agglomeration and suspended solids removal. Bentonite has a large specific surface area with a net negative charge that makes it

The Sixth “S” is Safety The Sixth “S” is Safety As lean manufacturers add a 6th S to the 5S process to emphasize safety, customizable signs and identification labeling that stick securely yet remove cleanly can help to optimize the workspace From the manufacturing floor to the warehouse, the 5S process of organizing the workspace to efficiently achieve consistent quality output is one of the foundational principles of lean manufacturing. With each S (Sort, Set in order, Shine, Standardize, and Sustain) accounting for a separate stage of the 5S approach, now a 6th S – Safety – is being integrated into the process. This emphasis is helping to ensure that safety is fully and consistently practiced, and new options in safety signs and labeling are helping to further optimize the process. “In 6S programs, signs play a key role in safeguarding the workplace and enhancing productivity by highlighting best practices and preventing or reducing accidents and injuries,” says Tina Huff, Group Product Manager at Avery Products Corporation, a commercial and industrial label manufacturer. “Such signs also play a vital role in keeping employees properly trained and staying OSHA or ANSI compliant.” Utilizing safety and identification labels on a variety of workspaces and production/warehouse equipment can be essential to establishing the safest operating instructions, procedures, processes, checklists and scheduling. The right label can make a big difference, and using one not designed for the job at hand can create problems down the road. 6S Fundamentals Site supervisors and warehouse managers familiar with the 5S process will appreciate how the 6S approach reinforces safety throughout all of the previous stages. Furthermore, new safety labeling options are now making it easier to print and post signs all over the facility, even when unique situations arise. As such, whenever information must be changed or updated, labeling that sticks securely yet removes cleanly can help to optimize the ongoing, iterative 6S process, particularly in terms of safety. Sort The first 6S stage, Sort, removes clutter and unneeded items from the work area. This leaves just the parts, tools, and machines necessary for daily use on the manufacturing or warehouse floor. Labels can be used in this stage to roughly sort and identify items that are used less frequently, which may be moved to an alternate location for occasional access, as needed. Set in order The second stage, Set in order, locates parts, people, tools, and equipment in the most efficient, ergonomic positions, so operators do not waste time or effort searching for needed items. Utilizing labels, along with tool shadow boards, and other visual identifiers can help to ensure that everything necessary on the manufacturing floor or in the warehouse is properly placed and ready to use. “To improve workplace efficiency, sign and identification labels can be integrated to clearly identify and classify parts, tools, and equipment,” says Huff. “The goal is to make things easy to find, so everything has a home.” Shine The third stage, Shine, ensures the workplace stays free of clutter, grime, and malfunction to prevent more serious work breakdowns or slow downs. In this process, cleaning as well as inspecting through cleaning is critical. However, insufficiently durable labels can become torn or otherwise unreadable, which is a particular problem with barcode labels. “To reliably perform through the Shine stage, it is important to use labels that are designed to withstand daily wear/tear, dirt, grease, oil, chemicals, and wash downs while providing good barcode readability,” says Huff. Standardize The fourth stage is standardization, which systematizes the most efficient work methods with clear standards. Utilizing schedules, checklists, and standard operating procedures are a key part of this process. “Placing sign labels on walls or equipment in the work area is a good way to increase their visibility,” says Huff. “This can provide a recurrent reminder of standard operating procedures to employees, so no one can say ‘I didn’t see it.’” Sustain The fifth stage trains and maintains the company’s standards until they become a habit for everyone involved. Posting sign and identification labels as close as possible to the actual work being done can be an important way to reinforce these standards until they are consistently followed. “Constant reminders to employees in the form of sign labels will help to sustain the 6S principles they need to follow,” says Huff. “Because research shows that people don’t ‘see’ signs after awhile, regularly updating the signs can help to refocus employee attention and behavior.” Safety – The Sixth S In 6S, safety is emphasized in every aspect of the lean manufacturing process. This ranges from plant logistics to equipment positioning/operation to the correct handling of parts/product to the wearing of safety gear. In warehouses, accurate labeling to properly identify changing inventories of parts in bins, totes, racks, shelving, or returnable containers can also enhance safety and efficiency. By improving barcode readability and inventory accuracy, this can minimize the need for employees to look for product, which reduces forklift and employee traffic on the warehouse floor. Because 6S is a continuous process, a highly involved organization will reorganize or improve its processes throughout the year, as well as accommodate inevitable changes in data, format, and safety regulation. As such, easily removing old labels and printing custom, updated ones can be a vital issue. Otherwise, employees can waste time scraping old labels off, using hair dryers, or even razor blades. They may be reluctant to update labels if it is difficult to get the old ones off, so may make do with sub-standard situations. The ideal solution would be signage and labels that are easy to install, durable enough to endure harsh conditions, yet comes off easily when necessary, leaving no trace. “Industrial labels used as signage or for warehouse part/product identification must be more durable than those used in an office, but also should remove cleanly when they need to come down,” says Huff. “For us, the key to accomplishing this was developing an adhesive that holds well but can be removed when needed. Achieving that

Protecting Facilities from Sugar Dust Explosions Protecting Facilities from Sugar Dust Explosions Sugar presents a combustion hazard when it is in a dry and dusty form. A fine sugar dust explosion can generate a pressure in excess of 100 psi within enclosed process equipment in less than 100 milliseconds. Where sugar dust and air are mixed together in a confined space, the consequences of a dust explosion are the greatest. Filtration equipment handling a combustible dust almost certainly contains a hazardous concentration of material under normal operating conditions. Other items of equipment may only temporarily carry a “combustible load” of hazardous material, perhaps during start up, shut down, loading or unloading. However, while that combustible load is present, the risk is no less severe. If the potential for a combustible load cannot be eliminated, protection measures are required. However, when this is the case many owners and operators of sugar dust processing or handling facilities may not fully understand the steps that must be taken to mitigate those risks. The NFPA Standards, for example, outline requirements that can range from improved housekeeping to installing dust-collection equipment and offering protective equipment for personnel. In addition, protection or hazard mitigation devices may also be required. Because these typically represent some capital expenditure, many owners and operators are seeking out information on the available technologies on the market. Explosion Protection Devices To protect process equipment and personnel, a hybrid of technical measures is often required. Among the options are passive devices like vents or containment systems along with active devices such as explosion suppression or spark detection and extinguishing systems. In addition, chemical or mechanical isolation devices are required to protect connected equipment and piping from propagating to a secondary event, which can often be more dangerous and destructive than the initial event. Explosion Vents During the early stages of a sugar dust or gas explosion, explosion vents open rapidly at a predetermined burst pressure, allowing the combustion process to escape to the atmosphere and limiting the pressure generated inside the process equipment to calculated safe limits. Venting is the most popular and widely adopted protection mechanism, in part because it is economical and requires little attention or maintenance once installed. “In the US, there are well over 20,000 vents applied every year on equipment,” says Geof Brazier, president of BS&B Pressure Safety Management, a manufacturer of a broad range of dust explosion prevention and protection technologies. Brazier adds that a single piece of equipment might even require multiple vents according to the NFPA 68 design calculations that assess dust reactivity and the volume as well as shape of the equipment to be protected. For decades, explosion vents have traditionally been designed using a “composite” approach that sandwiches plastic film between more resistant stainless steel sheets with holes, or slots, cut into it. These vents are designed to “open” at typically 1 to 1.5 PSI set pressure, a result of the slot and hole pattern placed into the sheet metal. Over time, however, this type of vent is prone to tears in the plastic film, which is the seal between the process conditions and the atmosphere. With this type of technology, the holes and slots in the stainless steel sheets can admit particulates and debris over time. In addition to being unsanitary, particularly for food processors, the build-up can eventually affect the functionality of the vent. “A vent that becomes heavier in weight due to build-up will open slowly and less efficiently, and ultimately the pressure in the equipment will be higher than expected which is a safety concern,” explains Brazier. In 1990, BS&B Systems patented the first single-section explosion vent, comprised of a solitary sheet of stainless steel in a domed configuration. Perforations around the perimeter to aid opening at the desired low set pressure are protected with gasket materials. The single-section domed design produces a vent that is more robust, lighter in weight and also largely eliminates the potential for build-up or contamination. In 2010, the company improved on the design by altering the shape of the dome to a unique compound geometry that delivers even greater rigidity for high vacuum or vibration applications. Despite its popularity, explosion vents will not work for every application. With venting, the combustion process will release a large ball of flame into the atmosphere that might be 10 times the size of the protected equipment for a few milliseconds. While this might be an acceptable consequence for equipment that is outdoors at a remote location, for applications within a plant compound or inside a building it could endanger personnel or equipment, and even lead to a secondary explosion external to the protected equipment. In cases where a flameball must be avoided, flame arrestors can be deployed. These devices are designed to absorb the pressure wave, flame and at least some of the dust that would normally be ejected by a vented explosion. The 3 dimensional flame arrestors applied downstream of explosion vents are heavy and when installed directly on top of a vent damage can result. To address this concern, companies like BS&B Pressure Safety Management provide a flameless system designed with the vent installed inside the flame arrestor. In doing so, the heavier flame arrestor is mechanically mounted directly to the equipment, reducing the weight load transmitted through the more sensitive vent and eliminating the risk of damaging the vent. It also serves the dual purpose of allowing for easy inspection of the vent and arrestor while installed. NFPA Standards require periodic inspection of explosion safety equipment. Suppression Equipment For processes where an explosion would ideally be prevented altogether, suppression systems are the best alternative. Explosion suppression equipment detects a dust explosion in the first milliseconds of the event and then signals extinguishing modules to release a flame quenching medium into the process equipment. This effectively stops the explosion in its infancy and only low pressure is produced that is safe for the protected equipment. “Suppression can be preferable for indoor equipment, simply because

From the Lab to Fab: Integrating Plasma Treatment Systems into the Manufacturing Process From the Lab to Fab: Integrating Plasma Treatment Systems into the Manufacturing Process For manufacturers of products that require a plasma treatment step for cleaning and decontamination, surface conditioning or to promote adhesion, specifying and integrating the required equipment to automate the process can be daunting. To start, many engineers only have a working understanding of plasma treatments. Plasma is a state of matter, like a solid, liquid, or gas. When enough energy is added to a gas it becomes ionized into a plasma state.  The collective properties of these active ingredients can be controlled to clean, activate, chemically graft and deposit a wide range of chemistries. However, even when plasma treatment is identified as a critical step in the manufacturing process, specifying and integrating the “tools” required (as the equipment is called) can be even more challenging. With so many applications and sizes of parts to be processed, standard off-the-shelf vacuum chamber solutions often do not suffice. In addition, as plasma treatment is increasingly integrated into existing production systems, so does the need to eliminate manual operations in favor of automated, “hands-off” production systems. Fortunately, today this does not necessarily mean purchasing a custom tool. Leading plasma equipment providers can semi-customize existing mature tools and technology to accommodate new or non-standard parts. This includes providing the necessary robotics for high throughput, automated loading and processing. “At least once a week we talk with customers about some sort of customization of our existing standardized systems,” says Walt Roloson, R&D Engineering Manager at PVA TePla, a company that designs and manufactures plasma systems. “I would estimate 60% of the equipment we deliver has gone through some degree of customization.” According to Roloson, a prime example occurred when PVA TePla was approached in November of 2017 by IMA Automation Medtech, a Swiss company that designs turnkey automated assembly lines for medical devices. The request was to specify a system that would replace an older, existing plasma treatment system that required manual loading with an automated solution. The small vacuum plasma chamber would be used to treat several “pallets” of 4-5 cm items in an automated batch process.  The parts were being treated with plasma as a critical surface activation step prior to the application of a coating. Each 12” x 12” aluminum pallet held three hundred items and the requirement specified a processing time of less than eight minutes from initial loading to unloading. The system was actually part of a larger manufacturing cell designed by IMA Automation Medtech that included a flexfeed device for loading packaged parts into the “pallets” on the front end, followed by the plasma treatment, coating, curing and then another coating/curing step. For this project, the customer decided not to return to the original equipment provider. “The customer was looking for a new plasma treatment solution that was not the original brand, so we were asked to find another vendor to provide a system that could be integrated into the automated line,” says Ruben De Araujo, a Process Engineer for IMA Automation Medtech. IMA Automation Medtech also wanted a plasma equipment provider that was willing to pre-test the tool to validate performance prior to delivery. “We wanted the equipment supplier to test parts to give us confidence purchasing the system,” explains De Araujo. “We were also looking for a company that was established enough to support the customer in Europe, because the line will be installed there.” After researching leading companies in the industry, IMA Automation Medtech decided PVA TePla met the requirements. “PVA was willing to customize the equipment to fulfill our requirements,” says De Araujo. According to PVA TePla’s Roloson, the initial specifications sent by IMA Automation Medtech were several pages long, complete with CAD drawings. However, as one-off unit, the original equipment had many custom elements such as a conveyorized track that transported the pallets in and out of the vacuum chamber. “We had never built anything like it, so it would have been a completely custom solution if we had to match it,” says Roloson.  “However, the general concept of automatically loading and unloading pallets with pick-and-place robots and treating parts in batches we have done many times.” To meet the requirements, PVA TePla proposed a semi-customized version of one of its smaller production-level vacuum chamber tools, because, “it could process pallets in batches and we already had a kit to add robotics to it,” says Roloson. Roloson says IMA Automation Medtech had approached other plasma treatment equipment providers as well, but the quotes for a completely custom system were exorbitant. By going with a standard tool instead, and having it customized, the customer ultimately saved both time and money. Whereas a custom system from scratch could require as much as 400-450 hours of engineering, a semi-customized system is typically less than half of that amount. Plasma equipment suppliers can also purchase components such as chambers, electrodes and pumps in bulk, often at discounted rates.  “The price for semi-customizing a standard model is just a much better value overall because most of the engineering is already figured out,” explains Roloson. Software Customization For the project with IMA Automation Medtech, Roloson says the most significant request was alterations to the communication and control software. As a company that supplies automated systems to the pharmaceutical, food and medical industries, IMA Automation Medtech must comply with Title 21 CFR Part 11 regulations established by the Food and Drug Administration (FDA) for electronic records. Part 11 requires companies to implement controls, including audits, system validations, audit trails, electronic signatures and documentation for software and systems involved in processing electronic data. With this in mind, IMA Automation Medtech decided not to send information through standard RS-232 or Ethernet connections and instead opted to utilize a PLC-based communications and control system, both for security and to work with the other component parts of the automated line. “Regarding the software interface to the rest of our machine, we decided the PVA TePla system should communicate with

CBN Hones for Improved Surface Finishing of Machined Superalloys CBN Hones for Improved Surface Finishing of Machined Superalloys Flexible cubic boron nitride (CBN) grit hones are ideal for restoring surface integrity of machined superalloys By its very nature, high-nickel, iron or cobalt alloy steels including Monel, Inconel, Incoloy, Invar, Rene and Hasteloy are some of the most difficult materials to machine. Because these superalloys are designed to deliver high strength at extremely high temperatures in components often found in “hot” sections of engines and turbines, the stresses and heat generated during machining are considerable. In this process, the edge of the cutting tool is exposed to considerable mechanical stress, strain and heat. High compressive and shearing forces attack this edge, increasing temperatures such that the cutting tools can begin to lose hardness. This can produce a “gummy” machining behavior and also cause work hardening. According to Janos Garaczi, president of Delta Machine Company, LLC., a company that specializes in machining complex, tight tolerance parts out of titanium, nickel alloys, stainless steel, aluminum, plastics and other exotic alloys, this is caused when chips do not break away cleanly from the workpiece. Instead, the material is just ‘pushed’ to one side. “It can be really difficult to turn or mill this type of material because it doesn’t produce a clear shearing action. Instead it just kind of pushes the material to the side,” explains Garaczi. “Gummy” machining is also the cause of heavy burrs in drilled holes or grooves. “The burrs are one of the biggest problems,” adds Garaczi. “Even during ‘grooving,’ if you cut the material from one side, it just pushes the burr to the edge; and if you approach it from the other side, it just pushes it back. It doesn’t want to break off the material cleanly. As soon as the tool gets a bit dull it gets a lot worse so sharp tools with the right geometry are key.” The general poor machinability ultimately compromises surface integrity of the parts, says Garaczi, which is problematic given that is one of the primary causes of failure of these types of components. Given the critical nature of the applications in which these components are utilized, most machined superalloy parts must therefore undergo a surface finishing operation to remove work-hardened layers and any heavy burrs. Doing so has additional benefits, including reducing the risk of oxidation and stress corrosion cracking (SCC). Although this has traditionally been achieved through an expensive, messy and time-consuming grinding process, new flexible hones are simplifying the task by incorporating one of the toughest, hardest materials on the planet – Cubic Boron Nitride (CBN). CBN combines the highest hardness with excellent toughness to provide the optimum surface finish. Flexible hones made of this type of material can be mounted on CNC equipment for automated operations or used in the field with handheld power tools to wear away work-hardened surfaces without inducing additional thermal distortion. Superalloys High-nickel alloy steels are prized within these markets because of the excellent resistance to corrosion and heat with strength, toughness, metallurgical stability, and weldability. These superalloys are a great choice for applications that require chemical resistance and strength at elevated characteristics. Their material properties include low expansion at severe temperatures and creep resistance under high stress conditions. As such, superalloys are widely used as material for the hottest parts of complex equipment including nuclear power components, high-performance automotive parts and jet engine turbines. Nickel, iron and cobalt alloys are also used broadly for aerospace components, medical devices, petrochemical and refining applications and thermal processing. According to Garaczi, with the right cutting tools milling nickel alloys and stainless steels is still limited as to the surface finish that can be achieved to at best 32 Ra. With turning, 16 Ra is possible, but most of the time it requires a grinding or polishing step. “Grinding is a very common process in these cases, but it is very time consuming and very expensive to have to grind a part. In some cases, it could take longer than the initial machining.” As a result, Garaczi says that Delta Machine often sends parts out for grinding or polishing, opting to not perform this type of operation in house. Flexible Hones For many machine shops, a flexible hone is a much more efficient tool for overall surface finishing. The low-cost tool is often used for sophisticated surfacing, de-burring, edge-blending and cleaning. Until recently, however, flexible hones with CBN abrasive were only available by special order. Now, the company that invented the Flex-Hone® Tool, Brush Research Manufacturing (BRM) of Los Angeles, Calif., offers CBN surface finishing solutions part of its standard product line. Somewhat resembling a spinning bottlebrush, the Flex-Hone tool is characterized by abrasive globules that are permanently mounted to flexible filaments that are attached to a center shaft. With its low-pressure, low-temperature abrading process, BRM’s CBN Flex-Hone tools can remove work-hardened layers and deburr parts without disturbing the underlying metallurgical structure. Standard CBN Flex-Hone tools come in sizes ranging from 4mm to 20mm in three different mesh sizes: 170/200, 800, and 2500. Larger sized products from 22mm to 38mm and additional mesh sizes are available by special order. Garaczi says he can see the advantage of being able to install a flexible hone into CNC equipment to automate the process and speed up the time when finishing superalloys and stainless steels. Garaczi is in a unique position, having started with the company as a machinist and eventually working his way to president and owner. As such, he remains responsible for much of the programming, set-ups and also purchasing. He says that when making decisions about what tools to purchase it is often on a project-by-project basis. However, if the tool can reduce cycle times versus its cost, it is an easy decision. “There are definitely scenarios where it would be good to be able to perform surface finishing of this type of material on CNCs,” says Garaczi. “It would really save a lot of time and extra processing cost.” For more information, contact Brush

A Movement to Protect Cyclists and Pedestrians from City Trucks A Movement to Protect Cyclists and Pedestrians from City Trucks Organizations nationwide are increasingly pushing for truck side guards and other measures to reduce deaths and injuries A rise in cyclist and pedestrian deaths in traffic collisions is spurring a push for safer streets regionally and nationally. Now, a growing coalition of organizations are calling for the implementation of vital safety measures, including side guards on large commercial trucks such as waste haulers, dump trucks, and box trucks. The guards prevent people from being pulled under the vehicle’s wheels and run over in the case of a collision. In Philadelphia, the recent deaths of Tomas Montanez, a bicyclist who was tragically run over by a right-turning dump truck, and Emily Fredricks, who was hit by a garbage truck making a right turn while cycling to work, has galvanized the community. “In the case of Tomas and Emily, I think truck side guards, along with other safety measures, would have prevented their deaths,” says Sarah Clark Stuart, Executive Director of the Bicycle Coalition of Greater Philadelphia, an organization that promotes safe cycling in the region. “Do not use the word accident when talking about these kinds of fatalities because they are not inevitable.” Pedestrians now account for 15 percent of all traffic deaths nationwide, according to a recent Governors Highway Safety Association report. However, in a 2016 tally in Philadelphia, the Bicycle Coalition of Greater Philadelphia found that pedestrians and bicyclists made up more than half of the city’s road deaths. After Fredricks’ death, the Bicycle Coalition has urged the city to adopt a number of safety measures. This includes a deadline for all trucks doing business in the city to install side guards. “We’re looking at a whole range of solutions,” says Stuart. “At the top of our list are truck side guards, along with protected bike lanes, speed enforcement, and other community level traffic calming approaches.” According to Stuart, to promote safer streets, the Bicycle Coalition is also working with various groups – including AARP, Uber, the American Heart Association, the Realtor Association, and Chamber of Commerce – to rally around Vision Zero principles. Vision Zero is a strategy to eliminate all traffic fatalities and severe injuries, while increasing safe, healthy, equitable mobility for all. First implemented in Sweden in the 1990s, Vision Zero has proved successful across Europe, and now is gaining momentum in major American cities such as New York City, Philadelphia, Los Angeles, Seattle, and Boston. “Companies and local governments that operate in major urban areas should take a careful look at side guards as a way to prevent tragic incidents involving pedestrians and bicyclists,” says David Biderman, Executive Director and CEO of Solid Waste Association of North America (SWANA), the largest member-based solid waste association in North America. According to Biderman, there is an increasing number of cities in the United States that have bike share programs, so there are many more cyclists on the road than there were five or ten years ago. “We need to be evaluating ways to protect the cyclists who may inadvertently run into the side of a truck, from being swept underneath the truck,” he says. “Side guards are a leading way to prevent that.” One example of such side guards is produced by Dur-A-Guard, a Union, NJ-based manufacturer of truck side guards, whose devices are Vision Zero compliant. Biderman points out that side guards can also mitigate the danger of a collision with increasingly distracted pedestrians, who may be texting while walking or listening to music with earbuds. “For a turning truck, an inattentive pedestrian would walk into a side guard and bounce off the truck instead of potentially being run over by it,” says Biderman. According to Biderman, there are 100,000 plus garbage trucks in the U.S., with trucks operating in every city. “You need to employ best practice techniques to prevent the worst from happening,” he says. “So we are encouraging waste haulers to be proactive, and not wait for an incident to occur before considering side guards.” One challenge of getting side guards implemented in a majority of waste hauling trucks nationally is the large amount of individual variation among the vehicles. “To implement side guards on a wider basis, it is important to customize them to any make or model of garbage truck because the vehicles come in a variety of configurations,” explains Biderman. “There are different kinds of trucks, and the bodies are different lengths. You need to be able to customize the side guards to fit the space between the wheels to prevent someone from falling into the space and being run over.” One of the nation’s highest profile uses of truck side guards so far occurs in New York City, which is requiring the safety barrier on 10,000 vehicles by 2024 as part of its Vision Zero Action Plan for ending traffic deaths and injuries. To comply with New York City’s Vision Zero program, Action Carting Environmental Services, a provider of non-hazardous waste management services for New York City and New Jersey, chose to retrofit its fleet of trucks with side guards from Dur-A-Guard. Dur-A-Guard worked with Action Carting to accommodate the various makes, models, and configurations of its fleet. To encourage such implementation, Biderman recommends the use of side guards that ease truck operation and maintenance. Some side guards, for instance, do not need to be permanently welded onto trucks. As an example, companies like Dur-A-Guard offer side guards that lift up or swing down on hinges to offer access beneath the truck. Another high-density, aluminum design is lightweight enough to be removed by one person. With the momentum growing toward utilizing side guards to reduce the traffic related deaths and injuries at the regional level, there is also movement at the national legislative level rising as well. In fact, one proposed federal law seeks to save lives with truck side guards. U.S. Senators Marco Rubio (R-FL) and Kirsten

Portable Friction Testing Can Prevent Slip and Fall Accidents and Deter Costly Liability Portable Friction Testing Can Prevent Slip and Fall Accidents and Deter Costly Liability Innovative portable friction testers enable quick, high volume, lab quality SCOF testing by virtually anyone on a variety of surfaces For facility managers of malls, grocery stores, and other large commercial buildings, ensuring safety and preventing slip and fall litigation can come down to documenting that their walkway surfaces meet safe standards in terms of available traction, particularly when wet – when falls are more likely. When slip and fall liability can top 5 or 6 figures per incident due to negligence, medical expenses, lost wages/future earnings, pain and suffering, and other factors, simply cleaning up spills on flooring is no longer an adequate response. Instead, a proactive plan is required that prevents clutter; speeds clean up, and routinely documents safe flooring traction. Today, this often entails measuring the Static Coefficient of Friction (SCOF) on a range of materials to meet the ANSI/NFSI B101.1-2009 Test Method for Measuring Wet SCOF of Common Hard-Surface Floor Materials. In this regard, SCOF ≥ 0.60 equates with high traction (lower probability of slipping); 0.40 ≤ SCOF <0.60 equates with moderate traction (increased probability of slipping); and SCOF < 0.40 equates with minimal available traction (higher probability of slipping). Since most slip and fall lawsuits allege that the property owner failed to provide a reasonably safe walkway, periodic documentation of safe SCOF measurements can help to assure safety, deter lawsuits, and minimize liability. While transportable manual strain gauges that are pulled by hand have traditionally been used for such measurement, these do not provide a truly reliable means of high volume testing on varying surfaces in multiple locations as needed. The devices are also complicated to use, requiring calibration and specialized training. Fortunately, a new generation of innovative, portable, friction testers are now enabling fast, lab quality SCOF testing in volume by essentially anyone without specialized training. With this capability, onsite measurement is easily conducted on a variety of surfaces, even at an angle or upside down. Even stairs, ramps, and inclines can now be readily measured. This can help to facilitate safety on a host of flooring materials, while documenting compliance and preventing slip and fall liability. Traditional Testing Limitations For onsite measurement of existing flooring, manual strain gauges are traditionally used to test the SCOF by facility managers of large commercial establishments. However, the problem with these bulky transportable units, pulled by an operator over horizontal test surfaces, is that the devices introduce human error. “With a manual strain gauge, the operator is trying to measure very minute numbers, but cannot pull the unit with a steadily increasing force until it starts to break free, and then stop exactly at that point to get an accurate number,” says John Bogart, Managing Director of Kett USA, a manufacturer of a full range of SCOF and surface property analyzers for various industries. Additionally, these units do not fit in narrow spaces such as stairs, and do not accurately measure areas such as ramps which are not level. The units also do not distinguish between individual spots in a larger area, but only give the average without variation – which can leave some areas out of compliance. Another challenge with manual strain gauges is that the devices do not readily measure mixed surfaces. This can be a problem not only with water, wax, polish etc. residing on the surface of the flooring material, but also with certain shoe sole surfaces, such as leather or high heels, which can significantly change the SCOF and make slip and fall incidents more likely. Finally, using such instruments can require substantial training. Even then, any variance in measuring technique between technicians can cause further differences in accuracy. Portable Testing Benefits In contrast to complex, traditional transportable units which can be larger than a microwave oven, easy to use, portable friction analyzers about the size of a hand mixer are now available. These can essentially be used anywhere onsite at locations with installed flooring. As such, utilizing them can help to ensure safe, compliant SCOF documentation that deters slip and fall litigation and liability. Examples of this include two handheld, battery operated models, the H94i and H37i by Kett. Both are designed so virtually anyone can quickly use them with minimal training, wherever SCOF measurement is needed. Operation is simple. The operator puts the unit on the surface to be tested, presses the measure key, and obtains the SCOF value in seconds, with accuracy comparable to lab models. The units rely on an electric coil assembly and a magnet to create an easily variable and precisely measureable force. When the operator presses the measure key, a voice coil motor increases the force exerted on a fixed slider until it begins to move. An integrated microprocessor measures the force vectors and calculates the SCOF. To enhance accuracy, both units automatically calculate averages to reduce operator judgment on mixed surfaces. Even with these capabilities, both instruments are compact enough to take measurements in smaller spaces (such as stair steps) so the operator can also determine SCOF variations. While the H94i must be used on a level surface, the newer H37i has integrated angle adjustments that allow it to be used at any angle from horizontal to vertical to upside down. This enables onsite SCOF measurement on ramps and inclines as well. The newer model, in fact, has been used to measure the SCOF of a variety of materials at slopes as high as 45° in a recent unpublished National Institute for Occupational Safety and Health (NIOSH) study. Compared to less flexible traditional methods, another benefit of the portable friction testers is the devices’ allowance for more versatile testing with a variety of mixed surfaces. This can include any solid or liquid on both hard and soft surfaces. According to Bogart, the ability to attach an interface layer onto the portable units enables multi layer simulation tests.

The Next Phase in Industrial Dust Explosion Protection The Next Phase in Industrial Dust Explosion Protection Among its directives, NFPA 652 outlines deadlines for sampling and analysis to identify potential risk areas for dust explosions in industrial facilities. Spotlight now turns to mitigation equipment For a wide range of facilities that manufacture, process, blend, convey, repackage, generate or handle items that could be categorized as combustible dusts or particulate solids, new NFPA Standards and even the first deadline to conduct a dust hazard analysis are now on the books adding to the responsibilities of owners and operators of such facilities. Explosions can result from an ignition of a combustible gas, mist or dust when mixed with air during processing, handling or storage operations. A rapid rise in pressure occurs in the containing structure, and if it is not of adequate strength to withstand the pressure, extensive damage and injury to personnel can occur. After a string of incidents in the early 2000s, organizations such as OSHA stepped up the requirements, as with the Combustible Dust National Emphasis Program of 2008, which is still in effect today. The NFPA (National Fire Protection Association), which has been issuing Standards and guidelines for decades, is doing the same with publication of NFPA 652 – Standard on the Fundamentals of Combustible Dust, in 2016. This new Standard consolidates best engineering practice and provides reference to all of the existing combustible dust standards in a single, overarching document that applies to all facilities that handle potentially explosive dusts. While the new Standard does an admirable job of unifying the various existing equipment and industry specific codes, NPFA 652 goes a step further by specifying – for the first time – a deadline for owners and operators of at-risk facilities to conduct a dust hazard analysis. “Perhaps the most important aspect of the introduction of NFPA 652, is that is requires all owners and operators of a dusty industrial process to do a dust hazard analysis,” says Geof Brazier, president of BS&B Pressure Safety Management , a manufacturer of a broad range of dust explosion prevention and protection technologies. According to Brazier, NFPA 652 specifies facilities must complete this dust hazard analysis within 3 years. However, recent revisions to NFPA 654 and 61 that additionally apply to many facilities have extended that deadline to 5 years. While a significant step in the right direction, NFPA 652 is essentially requiring owners and operators of at-risk facilities to confront and address an issue that many may not fully understand in terms of both the potential for such an event and what steps must be taken to mitigate those risks. The NFPA Standards, for example, outline requirements that can range from improved housekeeping to installing dust-collection equipment and offering protective equipment for personnel. In addition, protection or hazard mitigation devices may also be required. Because these typically represent some capital expenditure, many owners and operators are seeking out information on the available technologies on the market. Explosion Protection Devices To protect process equipment and personnel, a hybrid of technical measures is often required. Among the options are passive devices like vents or containment systems along with active devices such as explosion suppression or spark detection and extinguishing systems. In addition, chemical or mechanical isolation devices are required to protect connected equipment and piping from propagating to a secondary event, which can often be more dangerous and destructive than the initial event. Explosion Vents During the early stages of a dust or gas explosion, explosion vents open rapidly at a predetermined burst pressure, allowing the combustion process to escape to the atmosphere and limiting the pressure generated inside the process equipment to calculated safe limits. Venting is the most popular and widely adopted protection mechanism, in part because it is economical and requires little attention or maintenance once installed. “In the US, there are well over 20,000 vents applied every year on equipment,” says Brazier, adding that a single piece of equipment might require multiple vents according to the NFPA 68 design calculations that assess both dust reactivity and the volume as well as shape of the equipment to be protected. For decades, explosion vents have traditionally been designed using a “composite” approach that sandwiches plastic film between more resistant stainless steel sheets with holes, or slots, cut into it. These vents are designed to “open” at typically 1 to 1.5 PSI set pressure, a result of the slot and hole pattern placed into the sheet metal. Over time, however, this type of vent is prone to tears in the plastic film, which is the seal between the process conditions and the atmosphere. With this type of technology, the holes and slots in the stainless steel sheets can admit particulates and debris over time. In addition to being unsanitary, particularly for food processors, the build-up can eventually affect the functionality of the vent. “A vent that becomes heavier in weight due to build-up will open slowly and less efficiently, and ultimately the pressure in the equipment will be higher than expected which is a safety concern,” explains Brazier. In 1990, BS&B Systems patented the first single-section explosion vent, comprised of a solitary sheet of stainless steel in a domed configuration. Perforations around the perimeter to aid opening at the desired low set pressure are protected with gasket materials. The single-section domed design produces a vent that is more robust, lighter in weight and also largely eliminates the potential for build-up or contamination. In 2010, the company improved on the design by altering the shape of the dome to a unique compound geometry that delivers even greater rigidity for high vacuum or vibration applications. Despite its popularity, explosion vents will not work for every application. With venting, the combustion process will release a large ball of flame into the atmosphere that might be 10 times the size of the protected equipment for a few milliseconds. While this might be an acceptable consequence for equipment that is outdoors at a remote

Miniaturizing Smart Wearables for Fitness and Activity Tracking Miniaturizing Smart Wearables for Fitness and Activity Tracking Connected, “smart” wearables such as rings, bracelets, clothing and shoes are benefitting from tiny RF chip antennas that take up less PCB space and allow for more miniaturized devices Traditionally, small chip antennas used in Bluetooth-enabled devices have required a designated ground “keep out” area to minimize interference from other components and ensure the ideal radiation pattern for wireless signals. In some cases, this reserved space can eat up as much as 15 x 20mm of the printed circuit board. However, with the drive to further miniaturize connected “smart” wearables for fitness and activity tracking, new tiny embedded chip antennas are now available that mount directly above metal surfaces to save as much as 10-20% of board space. This has major implications for manufacturers of smart rings, bracelets, shoes, jeans, shirts and other apparel since the printed circuit board along with its coin-cell batteries typically dictate the minimum size of the electronics involved. Smart Wearables A wave of “smart” wearable devices has already entered the market to monitor everything from fitness and health to the physical environment. Often equipped with gyroscope, accelerometer, temperature and pressure sensors, GPS and even microphones, these tiny devices can track vital signs, sleep, emotions, stress, breathing, movement and even send/receive messages and alerts through text, audible sounds and even colors. As with any “connected” device, this information is then shared via wireless signal such as Bluetooth to a smartphone. Among the products already incorporating this type of technology are smart bracelets that monitor movement, body position and vital signs to detect if an elderly person has had a debilitating fall; a necklace that records voice memos before translating them into text; and even 8k gold plated rings with choice of gemstone that serve as activity trackers. Connected clothing and other apparel such as jeans, yoga pants and other apparel also now contain sensors designed to keep track of workouts, monitor body temperature, posture and movement. Not to be outdone, the 130.3 billion retail sports footwear market offers intelligent running shoes that connect to popular distance/speed tracking apps while also measuring acceleration, cadence, ground contact time and other factors to improve performance. Top of Form Embedded Chip Antennas To make this all work, each device must contain small RF chip antennas embedded on the PCB or behind the scenes underneath the encasement of the product. These chip antennas radiate and receive electromagnetic waves like other types of antennas do, but the most notable difference is their small size. In fact, today’s mobile phones incorporate a minimum of four antennas and up to 13 in some models. Smaller wearable devices may only contain one or two antennas. To work properly, chip antennas are typically ground plane dependent, meaning they require an appropriately sized and positioned ground plane to form a complete, resonant circuit. While the PCB can serve as the ground plane, the antenna itself must typically be placed on the edge of the board in an isolated section which is free from ground and metal components that would distort its radiation. Without the isolation distance, the performance of the antenna is significantly affected. “The ‘keep out area’ is fundamental to ensure the chip antenna can electromagnetically radiate to antenna applications, because everything affects the radiation pattern including the package size, where the antenna is mounted and its proximity to the human body,” says Manuel Carmona of Johanson Technology, a leader in high frequency ceramic components including chip antennas, High Q capacitors and EMI chip filters. According to Carmona, Johanson Technology has been able to eliminate the requirement for a designated ground keep out area through optimization of materials (ceramics and inks), manufacturing processes and RF circuit design. The new 2.4 GHz antenna can now be mounted directly onto the metal ground plane. The product measures 2 x 5mm and is designed for small coin-cell battery operated wearable applications where metal or a battery/display covers the entire length or side of the PCB. “With PCB real estate at a prime, the size and placement of the chip antenna is critical because as everything gets smaller it becomes increasingly difficult to place more components on the board,” explains Carmona. “Therefore, design engineers are looking to component manufacturers to deliver miniaturized solutions that occupy next to no real board space.” The design of the antenna itself is also critical to its range and performance. With smart wearables, radio interference or some other glitch could result in interrupted connectivity. There can be legal ramifications as well. As with any wireless device, products that utilize RF technology, including Bluetooth, to collect or transmit information are subject to regulation by the Federal Communications Commission (FCC). Therefore it is critical the device perform at the designated frequency and the design and placement of the antenna is critical to proper tuning. Despite the critical nature of the antenna, Carmona says it is often overlooked until late in the design process, at which point optimal antenna performance may not be achievable within the space provided. To assist with chip antenna design and selection, Johanson Technology offers a program where design engineers can send in a miniaturized device and the company will tune the antenna for optimum functionality. “A chip antenna that can be mounted over a ground plane opens up many applications for products that want to incorporate wireless,” says Carmona. “To date, we have received everything from smart shirt buttons to jewelry and other wearables in various shapes and sizes.” For more information, contact Johanson Technology at (805) 389-1166, e-mail antenna@johansontechnology.com or visit www.johansontechnology.com/ant. The company is located at 4001 Calle Tecate, Camarillo, CA 93012.

Trade Publications Remain Prime Target for Industrial Marketing, Branding Trade Publications Remain Prime Target for Industrial Marketing, Branding As trade magazines expand influence through online portals, the ability to target specific industrial prospects through feature length articles remains one of the most profitable forms of branding and lead generation Despite the increased focus on social media, tried-and-true industrial trade publications remain one of the best tools for reaching targeted industrial audiences. Now, as trade magazines continue to spread their influence through online portals, this influence is only getting stronger. With general content and articles that dominate major search engine rankings, trade publications are no longer simply about what goes in print. Today’s trade publications now have sophisticated online portals that offer magazine issues in digital edition format (flipbooks, laid out like the magazine) as well as greatly expanded online content that goes far beyond the information found in the pages of the latest print issue. For the generation that searches for much of its information online, these articles can get more “eyes” on them than ever before, often appearing at the top of the major search engine rankings. Within the posted content, which can range from news and new product announcements to industry trend articles, the holy grail of coverage are feature length (800 or more words) editorial articles that inform and educate the market while also potentially promoting a client’s product or service. When objective third parties are quoted, this type of feature article coverage can be one of the most powerful, credible forms of marketing in the industrial space today. “Trade magazine coverage – both print and now increasingly online – can deliver a powerful combination of branding along with direct lead generation,” says Jeff Elliott of Power PR, a company that for 27 years has written and facilitated placement of editorial features in industrial and commercial trade magazines. By way of example, Elliott cites the case of EonCoat, a developer and manufacturer of a new type of VOC-free, protective coating that prevents corrosion at industrial facilities. The longtime client of Power PR has benefitted from more than 200 articles in trade magazines print and online about its unique product offering. Over time, these articles have generated significant awareness and a substantial quantity of qualified leads. However, when a target prospect from a major water works company requested a meeting, Merrick Alpert, EonCoat’s president, says he was “stunned” when the engineer walked into the meeting with a prestigious trade magazine open to a feature article about his product and said, “This is why we contacted you. This is why we are here.” Alpert says the engineer then began to refer to specific content in the article: Here are some tanks you coated that are similar to ours; this person in the article was quoted as saying the coating eliminated rust, here are the benefits we like about your product… “The prospective customer had not only read the article, but also really internalized the benefits of the product that were reflected in the article,” says Alpert. According to Elliott, this is the power in feature length editorial coverage – the ability to explain in depth the value proposition of a product or service; to explain why a prospect should pay more for a product upfront because it saves money in the long run; to explain how a difficult-to-understand product works; or simply to create awareness for a product that is not known in the industry. “Many industrial companies have products that are ‘the best kept secret’ in their industry and they want to change that through feature length editorial articles in trades,” explains Elliott. The brass ring, however, is when these editorial articles include testimonial quotes that serve as credible third party endorsements. “There probably is no type of industrial marketing that is more credible than an article that includes testimonials,” says Elliott. “What that means is you can essentially harness the power of word-of-mouth and force multiply it out to a massive, targeted audience of prospects.” Best of all, in many cases posted trade articles remain online and at the top of the search engine results for years. So how do industrial companies secure feature article coverage in the trades? There are many avenues for generating feature article coverage, including directly approaching editorial staff, leveraging advertising buys or working with PR companies that facilitate such coverage. It also helps if the product in question is unique in some way, increasing its news value to editors. If it is not, then the article needs to successfully differentiate the item from the rest of the market. “Some manufacturers have a hard time initially verbalizing what is unique or interesting about their product. However, by going through a process of examining the primary benefits and how the product is different than other options on the market, this can often be formulated and included in articles. The secret, though, is to give the trade magazine what it wants – valuable content that informs and educates the market and not a blatant PR piece. “Trade magazines do not care about promoting a specific product or service. They want well-written, interesting and newsworthy editorial content,” explains Elliott. “However, if done correctly it is possible to include details of the benefits of a product and even testimonials within the context of such articles.” This “skill” in writing full length features that serves both the goals of the magazine and includes some promotion is one refined over time based on experience working with editors and understanding what will be seen as “too much.” “Most companies have hit a ceiling where the only types of articles they post on their sites or get in trade magazines are short news articles or product releases that are 2-5 paragraphs long with a photo,” says Elliott. “These types of articles are more of a ‘formula’ and really don’t impart much information. In short, the ability to create feature length editorial style articles requires a different approach and level of expertise. But when done properly, feature

Designing Dust Collectors with Expert Guidance Designing Dust Collectors with Expert Guidance Consulting with a specialist can help MEs ensure compliance and safe performance Dust collectors are used to capture, convey, and collect dust for a wide variety of manufacturing and industrial processes. Whether involving wood, plastic, metal, or chemical dust particles, this is done to improve safety by reducing fire, explosion, and dust inhalation hazards. When it comes to dust collection, however, the challenge for mechanical engineers (MEs) is that, by definition, mechanical engineering is one of the broadest engineering disciplines. As such, they are often tasked with designing machinery or systems that provide a variety of functions, including generating power/electricity; conveying people/materials; and furnishing HVAC/refrigeration. With such a broad focus, MEs are often unfamiliar with some of the technicalities of dust collection safety code compliance, since dust collection systems account for just a tiny fraction of their work. When MEs have questions regarding dust collection on topics ranging from airflow to meeting NFPA and IMC codes, seeking guidance from an industry expert can help to achieve compliance, safe performance, and better indoor air quality. Design Challenges Since dust collection is so important for safety – and depends on factors such as the dust sources, air filtration, facility usage, and HVAC – it often has to be customized and not based on previous design plans. Peter Levitt, a NFPA member, who for over two decades has been a committee member of NFPA 664, which oversees revisions of the woodworking code, outlines the five main components of a dust collection system. These components include a hood to confine the dust at its source; a duct system to convey the dust; a fan to provide hood suction and maintain transport velocity in the ducts; a collector to separate the dust from the air stream and a device to store the collected dust. “When dealing with dust collection, MEs often have questions about duct sizing, and how much air to allocate for suction at the hood and at each woodworking machine,” says Levitt. “They may not know what the velocity should be in the ducts, and often do not know what the code specifies for the dust collection system.” Levitt notes that a properly designed and maintained dust collection system will dramatically enhance shop safety. This can not only reduce the risk of dust explosion and fire, but also help to minimize any dust inhalation while improving indoor air quality. “MEs are often not aware of the incompatibility of some machines, materials and processes for a dust collection system,” says Levitt. As an example, he cites a relatively common mistake. “In a wood shop you might have a grinding wheel to sharpen tools,” he says. “However, you cannot have common suction at the grinder because any sparks produced could ignite the wood dust and trigger a fire or explosion. So the grinder cannot be part of the dust collection system.” He adds that for a similar reason, PVC ducts should not be used with a dust collection system. The problem is that if static electricity is generated by the dust being conveyed in the duct, it can also cause a dust explosion. Best Practice Dust Control To help MEs learn best practice options for dust control, Levitt, who is also a product manager at Sternvent, Inc., conducts lunch and learn presentations at engineering firms. Union, NJ based Sternvent has over 50 years of experience in the design, manufacture, and application of dust collection systems. The company, which specializes in systems for the wood, metal finishing and chemical industries, provides up-to-date guidance for compliance with NFPA, OSHA and IMC. In the presentations, Levitt covers topics such as determining the location of the dust collector, explosion venting, spark detection/suppression, and NFPA 664 recommended exhaust requirements. He also surveys the range of dust collection system equipment choices from indoor enclosureless positive pressure to outdoor shaker and pulse jet types. While Levitt provides guidance, he defers sales to the Sternvent network of professional sales representatives, who have developed ongoing, trusted relationships with MEs. One aspect of dust collection that needs more attention is the design of the ductwork, according to Levitt. “For good airflow, good duct work is essential. Even with a powerful dust collector, if the duct work is not designed properly, you will have so much airflow resistance you won’t have enough airflow or suction.” Another aspect that he says often needs consideration is whether the dust collector is located indoors or outdoors and how that affects filtered air. “Typically, the dust collector is located outdoors for fire safety,” says Levitt. “However, in regards to filtered air, if you don’t return it properly, then in winter you will have a hard time heating the building. The result is like having a fan exhausting the warm indoor air outside.” While many factors should be examined in designing a safe and effective dust collection system, it is also important to not over specify it. “If a dust collector is over-sized, it will not only cost more than required, but also create excessive noise due to high velocity airflow in the ducts,” concludes Levitt. “Knowing your options up front by collaborating with an expert can help MEs deliver the best equipment for the situation at the best price.” For more info, call 908-688-0807; Fax: 908-688-0718; email Peter Levitt: plevitt@sternvent.com; visit www.sternvent.com; or write to Sternvent, Inc. at 5 Stahuber Ave, Union, NJ 07083.

Simplified, Versatile Aviation Eddy Current Testing Simplified, Versatile Aviation Eddy Current Testing Innovative flaw detection devices can streamline the testing of a wide variety of aircraft parts while easing lift-off and operation In aircraft maintenance and repair, eddy current devices have long been used to nondestructively test (NDT) wheels, struts, propellers, airframes, hubs, engine components and other parts for flaws such as cracks, fatigue or corrosion in a variety of metals such as aluminum and steel alloys. This traditionally involves multiple eddy current test instruments to address the full scope of work, which can involve inspecting surfaces, welds, tubing, and bolt holes. “When it comes to metal fatigue testing, there are a number of different ways to test the materials,” says Beau Klingbeil, General Manager of Eclipse Aerospace Inc.’s Chicago service center, which provides complete servicing of the manufacturer’s twin-engine, single pilot jet line of aircraft. “Eddy current is the least expensive, least invasive way of doing those tests so we typically end up using it on a weekly basis.” While meter type instruments are traditionally limited to aluminum airframe inspection with a set frequency and probe type, more sophisticated impedance plane units that can be set to a variety of frequencies allow for testing in a much wider range of applications. However, these versatile tools can be quite complicated to use – almost too complicated – even for those with some training. Fortunately, for busy A&P mechanics that do not specialize in NDT testing, yet are responsible for a breadth of repairs, streamlined testing using sophisticated impedance plane devices is now possible. These devices can provide very accurate test results and dramatically simplify operation while utilizing a wide range of probe types. Simplifying Lift-Off and Operation All-digital eddy current instruments, utilizing incremental push button adjustment instead of rotational knobs, are common in aviation repair. However, operating the devices can be complex to the point that mechanics unfamiliar with their peculiarities are often forced to pull out the manual to set up and use them. This is particularly true when it comes to lift-off, which is required at the start of eddy current testing to offset any surface abnormalities or hand movement that could distort accuracy of the measured material. During lift-off with such instruments, mechanics typically end up pressing buttons and waiting for the computer processor to rotate through the set-up process, which can be agonizingly slow. “With most digital eddy current units, you push buttons to incrementally set a variety of different parameters,” says Klingbeil, who is an A&P mechanic and Level 2 certified in eddy current testing. “You have to constantly go back and forth to adjust things like the single amplitude, phase angle, and vertical/horizontal position.” Instead, Klingbeil found a better alternative by turning to an impedance plane eddy current instrument by Centurion NDT, a Streamwood, IL based manufacturer of portable eddy current and ultrasonic equipment. “I can step up for an eddy current test in minutes and be ready to go with the NDT-1100,” says Klingbeil. “The portable unit is very easy to use and performs a variety of tests.” The instrument, which is about the size of an iPad with an LCD screen, will locate surface and near-surface defects and conductivity changes in magnetic and non-magnetic materials, and can cover about 85% of the applications for eddy current testing that might be performed. This includes crack detection; sorting classes of materials according to hardness alloy, carbon content, tensile strength, and grain structure; as well as measuring coating thickness, sheet thickness, and the relative conductivity of critical materials. Unlike traditional all-digital units, the instrument has an automatic balance/null feature that substantially reduces set-up time for manual operation. By moving the probe and turning a phase control knob on the front panel, lift-off can be completed in seconds. According to Klingbeil, the unit is very easy to use at lift-off and during operation, which tends to eliminate common errors of adjustment that can otherwise occur. “For me, the reason it’s so easy to use is that you just enter the frequency with a push button, and then turn knobs to fine tune everything else,” he says. “Because of how easy it is to use, I don’t deal with a lot of false indications. It eliminates most of those.” In regards to ease of use, he adds, “When you’re adjusting things like the single amplitude, the phase angle and even the vertical and horizontal position, you don’t use a push button that functions very incrementally. Instead, you can fine tune it exceptionally well and accurately with knobs.” Since mechanics often must deal with a full range of testing from the airframe to the wheels, it is also important to select an eddy current instrument that accommodates a large array of probe and coil types. In the case of Eclipse Aerospace’s Chicago service center, Klingbeil stocks about a half dozen probes from Centurion NDT. The manufacturer of portable eddy current and ultrasonic instrumentation makes a wide variety of probes and coils. Digital frequency selection, probe drive and impedance adjustments allow the operator to optimize system performance for whichever probes or coils are selected. According to Klingbeil, the Chicago service center utilizes two pencil probe testers with different frequencies, two probes for wheel specific testing, and two bolt hole probes to test different types of wheels. “The pencil probe testers have different angles because some areas we have to NDT are hard to reach,” says Klingbeil. “One pencil probe tester is straight, one is angled 90 degrees to improve reach.” Among the most specialized probes are those utilized to detect heat damage along the wheel bead seat, the critical area where the rubber edge of a tire contacts the wheel. In this regard, Centurion NDT offers an extensive library of wheel bead seat probes, which accommodate the variety of wheels manufactured for the industry. To improve accuracy and ease eddy current testing of the wheel bead seat, the company also offers a wheel turntable accessory. Instead of manually

Damage Free Sign Labels for Hospitality Industry Damage Free Sign Labels for Hospitality Industry Customizable sign labels used to notify, instruct, and provide safety guidelines can be removed cleanly from surfaces, dramatically reducing repair and repainting costs Throughout the hospitality industry, signs are used virtually everywhere from the front door and reception/lobby, to restaurant guest and kitchen areas, to conference rooms and gift shops, to the routes and maps for emergency exits. Signs are used in many ways, whether informal, formal, or mandated by law. Permanent signs may not be an option when the information changes and needs to be updated. This can occur when policies and procedures change or during events, such as business conferences, seminars, expos, or conventions. In such cases, temporary signs are used for directional navigation, identifying rooms and escape routes, as well as to provide warnings and precautions about various hazards. This is particularly important when any construction, remodeling, refurbishing, or maintenance is occurring. In such temporary situations, the traditional signage options for administrators and facility managers are limited. Because signs can be located in high traffic areas and subjected to harsh cleansers, the sheets of paper, cardstock, sheet protectors, laminated sheets, and posters used must not only present a professional image, but also stand up to the environment and even meet specific safety codes. Floor stands and easels can block aisles and foot traffic, and can even create trip hazards. This is where the problem lies. Since many signs are not designed for high traffic use, they may not look professional or be resistant to wear and tear from frequent touching, handling, or the cleansers used in such environments. As a result, they are damaged easily and must be replaced frequently. Many signs can also cause considerable damage to the underlying surfaces when taped, tacked, nailed or screwed to walls, glass, or equipment, which can hasten the need for costly repair and repainting. Sign removal can also leave behind unsightly residual tape or adhesive. This is exacerbated when signs include information that is routinely changed or updated. With hotel repair, replacement, and renewal one of the industry’s largest expenses, accounting for 8–12% of total revenue, wall painting and repair can represent a sizeable share of the cost. As such, the ideal solution would be signage that is easy to install, durable enough to endure heavy traffic, yet comes off easily when necessary, leaving no trace. This can significantly reduce the need for facility maintenance, freeing up resources for higher priority purposes. “Commercial-grade labels used as signage must be more durable than those used in a lower use area, but also should remove cleanly when they need to come down,” says Tina Huff, Group Product Manager at Avery Products Corporation. “For us, the key to accomplishing this was developing an adhesive that holds well but can be removed when needed. Achieving that balance is harder than it sounds.” As a result, Avery created Surface Safe Sign Labels – an exclusive, proprietary product specially engineered to stick securely yet remove cleanly without damage or residue to painted walls, doors, windows, furnishings, equipment, and other interior surfaces. These “labels used as signs” are made of durable, commercial-grade material that resists water, chemicals and even abrasion. Available in a variety of sizes, they print easily on standard laser or inkjet printers, opening a world of possibilities for custom, do-it-yourself signs. Unlike standard office labels with a paper substrate, the topcoat of the commercial-grade sign labels is waterproof and chemical resistant, while its polyester substrate is a durable, scuff and tear-resistant film. These qualities are ideal for safety-related signage mandated by regulation or required by administrative policy. Whenever construction, remodeling, or maintenance changes hotel or restaurant evacuation routes, for instance, management is responsible for posting signage for interim routes, which the removable Surface Safe Sign Labels can easily accommodate. Administrators, facility managers, and safety officers will also want signs compliant with OSHA 1910.145 (Specifications for Accident Prevention Signs and Tags) and ANSI Z535.4 (Product Safety Signs and Labels). Although standardized safety signs can be purchased out of catalogues, there is often a need to modify or customize mandated signage as conditions or formats change. On-demand printing solutions, however, have traditionally required a large upfront investment of thousands of dollars, including a specialized sign and label printer, software, labels, and ribbons. In response, industry innovators such as Avery have developed a simplified, flexible approach using standard laser and ink jet printers. The company’s free online Design and Print Software enables customizable printing utilizing a hundreds of templates for use in facilities, for events, and for safety signage. Hospitality staff can create and print their own informal, formal, or compliant labels from pre-designed templates or create them from scratch. Most find the process intuitive, since it resembles creating an office document from pre-designed templates. The removable labels can be printed on demand in whenever they are needed, and will stick securely on every surface in hotels and restaurants including paint, drywall, windows, wood, plastic, and metal. Because they peel off cleanly without leaving any residue, they can even be reused as well. With the variety of signage used throughout the industry, the ability to conveniently print new sign labels in minutes and cleanly remove the old will go a long way toward keeping the whole hospitality community safely up to date and professional looking without the hassle, mess or cost. For more information visit www.Avery.com/signs.

Increasing the Packaging Speed of Raw Food Service and Retail Bacon Increasing the Packaging Speed of Raw Food Service and Retail Bacon Meat processors are increasingly packaging raw bacon using dedicated, high throughput interleavers and card dispensers that dramatically increase packaging speeds of raw bacon The U.S. pork bacon market is growing at an unprecedented rate. According to National Pork Board figures compiled by Nielsen Research, the U.S. pork bacon market was $3.3 billion for the 52 weeks ending April 28, marking a rise from $3.1 billion the previous year. This substantial growth in the market is fueling a demand for meat processing companies that can provide a higher production volume of raw bacon for use in the food service and retail industries. Therefore, to capitalize on this demand, meat processors are increasingly turning to newer, higher speed packaging solutions that include dedicated interleavers and card dispensers that maximize throughput of raw bacon. By including automated stacking, the equipment also eliminates unnecessary labor costs while reducing the risk for injuries due to repetitive motion. Dedicated, High-Speed Interleavers Interleavers are automated, high-speed machines designed to dispense sheets of paper, film or cardstock under, between or around meat, cheese and other products for portion control, inventory control and more sanitary handling. This includes greaseproof paper, parchment paper, plastic film, or bacon boards added after slicing and before final packaging For raw bacon used in food service operations, including restaurants, interleaved paper is often used to separate bulk portions of sliced bacon. The alternative is to pack raw bacon as individual slices side-by-side on paper in what is known throughout the industry as lay-flat packaging. In both cases, interleavers are often combined with counter/stacking modules that automatically count and stack the portions for boxing or gas flush packaging. For raw bacon packaged for retail sale in grocery stores and other outlets, packaging typically involves the use of interleaved cards, or L-boards, which come pre-printed and branded with product and nutritional information. The process begins with the bacon being sliced and shingled in specific units of weight, followed by the L-board then being interleaved and folded over the top of the product. The final step involves vacuum-sealing the bacon in clear plastic. The Need for Speed In the production line, the interleaver operates between the slicer and the final packaging equipment, with the slicer typically capable of the highest processing rates. Although this speed imbalance is generally acceptable, there are times when a processor needs to achieve higher packing speeds to satisfy an increase in demand. This means the interleaver or packaging equipment, whichever is slower, effectively dictates the maximum throughput speed. If these systems are older or poorly designed, they can quickly become a bottleneck. In cases like these, the options are to add more slicing lines or replace the equipment with models that run faster. “The bottleneck [in bacon processing] is usually with the interleaving or packaging equipment,” explains Bernell Martin, President of John F. Martin & Sons, a meat processing company that supplies raw bacon to both food service and retail outlets. “So when the process needs to move faster, it usually means switching out equipment to generate that speed.” According to Martin, John F. Martin & Sons operates five packaging lanes, with three including dedicated interleavers for L-Boards. Previously, the maximum throughput rate was only 38 boards per minute, but due to increasing demand that needed to increase to 54 boards per minute at a minimum. After some research, Martin decided to install a ProLeaver Card Dispenser from Packaging Progressions, a company that specializes in the design and manufacture of automatic, high-speed interleavers, stackers and card dispensers. Martin says the ProLeaver Card Dispenser is particularly popular among meat processors because of its exceptionally high throughput speeds, which exceed the industry norm by as much as 40%. For retail packaging of bacon, the unit can reliably feed up to 80 cards per minute without losing time to jams, missed cards, and double feeds. John F. Martin & Sons also sells bacon to food service operations. This requires traditional paper-feeding interleavers. Based on a sheet-weight of half-a-pound of raw bacon, the equipment can interleave up to 120 sheets per minute for a total of 3600 lbs. of lay-flat bacon per hour – nearly twice that of traditional systems. To achieve these kinds of speeds and maximize uptime, Packaging Progression’s interleavers vary from standard industry offerings with unique features such as servo controlled product and paper synchronization; power-assisted paper unwinds; encoder enabled positioning for precise placement and jam free diverting; bacon debris filtering to prevent false paper feeds and reduce jams; paper saving draft presence sensing; jam detection logic to reduce paper jams; an automatic portion centralizer; and high speed servo controlled vertical diverters for stacking. These design improvements essentially increase the accuracy and tracking of the items and the inserted paper or card to achieve high speeds reliably without double-feeds or paper jams. “For paper feeders, it is critical they do not jam, which some are known to do,” explains Martin. “So run speeds are important, but so is the amount of uptime. It can’t be a maintenance nightmare.” Automating Manual Processes Despite the available automated equipment, there still are several areas where manual labor is still often utilized in the bacon packaging process. By automating these steps, meat processors can reduce labor costs as much as 90%, eliminate repetitive motion injuries and increase throughput. For example, when packaging bacon for retail after the L-board is inserted and folded over, the product must often be manually rotated by a worker so it enters the packaging machine at the proper orientation. “Typically, sliced bacon is loaded onto L-boards in only one direction,” explains Martin. “With most equipment that means someone has to manually rotate the product 90 degrees so it loads properly into the packaging machine.”   This is spurring the development of equipment solutions, including an automatic folder/turner model soon to be released by Packaging Progressions. In many processing plants, the counting

OEMs Opt to Eliminate In-House Lamination Operations OEMs Opt to Eliminate In-House Lamination Operations OEMs that make parts or products from flat-rolled steel, aluminum and other metals are eliminating in-house lamination operations and outsourcing to experienced coil coaters instead For OEMs that apply laminate films to metal parts or apply coatings to as decorative finishes, the in-house manufacturing process requires a significant investment in equipment, plant floor space and ongoing maintenance for what can be a very temperamental process. Not only that, but failure to precisely control what can be a very temperamental process can lead to laminates which do no bond properly or wrinkle, leading to excessively high scrap rates and even product returns. For this reason, OEMs are increasingly outsourcing the application of laminate films to experienced coil coaters who can provide several alternatives: steel, aluminum or other metals in coil or sheet form with pre-applied (dry) adhesive; or fully laminated product that eliminates in-house processing altogether. The result for OEMs can be significant, both in terms of speeding production and reducing operational costs. However, when paired with the fact that experienced coil coaters can produce high quality laminated products, it becomes a win-win scenario. “Many OEMs are not fully aware of the alternatives for outsourcing part of, or all, the lamination operation to coil coaters,” explains Dan Chin, president of Universal Chemicals & Coatings (Unichem), a company that specializes in custom adhesives and coatings used in coil processing. “This is often simply because they have ‘always done it the same way’ – in house – but they can get a high quality laminated product and eliminate the costs and headaches associated with the process.” Laminates The use of laminate applied to metal to fabricate parts or products is widespread throughout manufacturing. Decorative finishes provide the look of stainless steel, brushed copper, and wood grains, as well as a variety of colors, imprints, and a range gloss levels. Laminate films can also serve a functional purpose by providing scratch or chemical resistance. Some of the more common applications including appliances (refrigerators and freezers, washing machines, dishwashers, microwaves, range or fume hoods), construction products (insulated wall panels, garage doors, roofing products) and the mobile and manufactured home markets (walls, door panels). Applying laminates to metal requires multiple steps. First, the metal is prepared by chemically cleaning and pre-treating. A liquid adhesive or film laminate is then applied to the metal and cured in an oven. The laminate film is then bonded to the metal as the adhesive coated metal exits the oven and the laminate is fed into nip rollers to join the laminate to the adhesive. The laminated metal is then cooled. According to Chin, in each step of the process there can be challenges which can lead to poor bonding or delamination. “All kinds of things can happen during a non-continuous laminating process,” says Chin. “You can have issues with bonding caused by the cleanliness of the metal, improper application of the adhesive or insufficient oven temperatures. There could also be misalignments of the laminate that cause wrinkles in the film.” Chin says this can lead to extremely high scrap rates in excess of 20%. Worse than that, OEMs may experience product returns and negative reviews due to delamination that occurs on a delayed basis once the product is in the field. “If there is an issue with the bonding of the laminate, it can manifest later when a product is already in the hands of the customer,” says Chin. “Normally there would be quality control testing in place to ensure that doesn’t happen, but it is still possible. By the time the OEM finds out, it can become quite costly.” Outsourcing to Coil Coaters According to Chin, one option for OEMs is to turn to experienced coil coaters who can pre-apply B-stage adhesive to virtually any metal substrate. The B-stage adhesive is designed to reactivate and cure within a specific temperature range to bond the laminate. This eliminates several steps and can lead to a higher quality laminate bond. “From a quality standpoint, you are going to get excellent uniformity of the adhesive applied [by a coil coater] and it will be properly cured,” says Chin. “Then, basically all the OEM has to do is laminate the film to the metal.” Another option is to eliminate the entire process completely. This eliminates the need for in-house labor, application equipment, curing ovens, and environmental emission control systems. “Typically, the coil coater has a lot of experience running these types of products, so they can dial in the adhesive thickness and control the curing and laminating temperatures very closely to ensure the proper bond,” says Chin. “That is going to translate to higher quality laminated product.” Coil coaters must also guarantee scrap rates below a certain level. “There is no testing the OEM will need to do, other than spot checks for their own quality monitoring process. The coil coater takes care of all that,” says Chin. Chin adds that laminated coil can also be easily cut to just about any size, ready for stamping, forming or other finishing operations. This can eliminate several additional in-house steps and simplifies the process of maintaining an inventory of laminated metals in different sizes. Adhesion Challenges Experienced coil coaters are also better equipped to handle difficult adhesion challenges, often with the help of adhesive formulators like Unichem that can deliver custom formulations and provide other advice about the lamination process. “As an adhesive formulator, we can customize the adhesive to match more exactly what the OEM is trying to accomplish,” explains Chin. “There are times the adhesive company, which has a specific catalogue of products, doesn’t have a solution that works for specific applications.” One example is adhesives formulated to be more “forgiving” in terms of temperature curing ranges. This can help OEMs that have challenges with oven temperature or consistency across the width of the coil. “By working with the OEM or coil coater and understanding the parameters, we can help to dial

Architects and Designers Transform Walls into Multipurpose, Functional Surfaces with Fabric Wall Finishing Systems Architects and Designers Transform Walls into Multipurpose, Functional Surfaces with Fabric Wall Finishing Systems New alternative to paint and wallpaper opens a host of creative possibilities, while support is available to tailor the work to specific projects Architects and interior designers are discovering new creative, functional possibilities by utilizing versatile, performance based, stretched fabric wall finishing systems for commercial and residential work instead of typical paint or wallpaper. The benefit of a stretched fabric wall surface is that it transforms a wall into a beautiful, functional surface. It has acoustical properties that reduce noise and sound transmission through walls; is tackable like a bulletin board; and can withstand high impact in high wear areas so is very low maintenance. The system is also versatile since refreshing the walls or updating the colors requires only changing out the fabric. A variety of fabric types, colors and patterns are available. Floor-to-ceiling, high definition graphics can be printed on the fabric. Various multi-panel designs can be installed from railroad track designs to abstract, curved, and custom shaped patterns using flexible track. With so many options, site fabricated wall coverings can be used to conform to most architectural features. Such fabric wall finishing systems are easily installed on site, and ample assistance is available to help with design, specifying, and special circumstances. Beyond Status Quo Paint offers little functionality or protection to the walls it covers. It does nothing for acoustics and scuffs easily, so maintaining it in high-traffic areas requires constant effort. Wallpaper is decorative. However, it is low-performance, providing little else and is even harder to maintain than painted walls. “While it is nice to have something warmer than cold, hard walls in a design space, we never use wallpaper,” says Dawn Sophia Ziemer, Principal Interior Designer at Kruger Bensen Ziemer Architects (KBZ), a Santa Barbara, CA based architectural design firm. “Wallpaper is difficult to repair or replace if it gets damaged; you have to seam it.” Like a growing number of architect and interior design professionals, Sophia Ziemer has found that utilizing fabric wall systems such as those from Fabricmate Systems, a global supplier of high performance wall surface solutions, can provide a warm decorative feel along with important functional benefits. She says that one of the main reasons her architectural clients select fabric wall systems is to improve acoustics. This often involves muffling background noise in a variety of settings to ease conversation. “Acoustics is a growing area of concern in architectural interior design, so we are always looking for ways to enhance it,” she says. “In open areas including entrances, foyers, and work areas you do not want the sound reverberating off of the walls and ceiling. Deadening the sound makes the space more functional.” According to Sophia Ziemer, KBZ uses the fabric wall systems in a variety of environments. “In K-12 through university settings, we often use Fabricmate in classrooms, multi-use rooms, and cafeterias to quiet things so it is easier for kids to hear the teacher and concentrate,” she says. “In municipal work, we have used it in fire stations and a recreation center, usually on walls or ceilings, to quiet background noise.” To accommodate the diverse needs of design professionals, site-fabricated wall finishing systems can be installed on top of any existing surface, so can be used to quickly refresh a site’s look, or for complete remodels and new installations. Installation involves panels that consist of three parts: a fabric covering, a backing material, and a fabric mounting frame. The fabric covering is stretched over the backing and held taut by the fabric mounting frame. This allows the panel surface to spring back when struck, effectively mitigating visible damage allowing for years of performance. The excess fabric is rolled into the frame for a clean look. The frame and backing can be reused, and the fabric changed out as desired. The backing fills in the frame and covers the wall, providing a pinnable bulletin-board like surface for tacking things up, along with impact resistance and the ability to absorb reverberated sound waves that would otherwise bounce off the walls. The fabric mounting frame holds the fabric in place. Sophia Ziemer says that the capability of the fabric walls to tack up work and designs helps to make wall surfaces more useful to clients and the design community. “Because the fabric wall can serve as a tackable surface, classrooms often use it to pin up classwork or study aids,” she says. “At universities, we typically use it in dorm lounge areas as attractive bulletin boards to pin up notices. In fact, we often use it to pin up our own design work here at KBZ when we are working on projects.” From a design perspective, the fabric wall approach is also helping to expand options. “Clients want more interesting spaces, so we have to be more creative,” says Sophia Ziemer. “Rather than just the typical suspended ceiling application, we are trying to create more interesting ceiling structures. Because the design and functional capabilities of the fabric walls also apply to ceilings, this opens up intriguing possibilities.” In terms of functional design, however, one of the more successful applications that Sophia Ziemer points to involves a project with curved walls at Ventura Community College in California. “Fabricmate helped us quite a bit on a big computer commons area with several hundred workstations in a big open space,” she says. “Our acoustical engineer designed a curvy wall to help break up the sound and keep it from bouncing around. He wanted a soft surface on it, so we faced it with stretch wall, which helped to further deaden the sound.” According to Sophia Ziemer, the fabric wall provider’s assistance helped to tailor the work to the specific project. The company, for instance, will make recommendations for layout, materials, application methods, installation timing, even product and installation warranty requirements based on the specified aesthetic, acoustical,

Functional PVD Coatings Improve Medical Device Performance and Life Functional PVD Coatings Improve Medical Device Performance and Life By applying PVD coatings to surgical instruments, implants and other medical devices, OEMs can increase value and differentiate products with functional properties that go well beyond color-coding for identification As the medical device industry continues to grow rapidly, manufacturers must contend with a variety of challenges if they wish to differentiate products in a highly competitive market. With this in mind, greater emphasis is being placed on the functional coatings that are applied to stainless steel, titanium and other substrates of critical medical devices from implants to scalpels, needle drivers, bone saws, and reamers. When manufacturers first began coating instruments, the primary purpose was to improve the aesthetics of instruments and improve identification during surgery. Titanium nitride, with its easily recognizable gold color, quickly became the coating of choice for this purpose. However, OEMs are now looking to move beyond aesthetics by applying titanium nitride and other innovative PVD coatings to improve wear resistance, reduce galling between sliding component, increase lubricity and even help retain sharp edges on cutting instruments. These same coatings can also deliver other important functional benefits, such as providing anti-glare surface for bright operating rooms, antimicrobial properties and anti-fouling in the presences of blood and tissue. In some cases, it can even potentially turn devices into multiple re-use items, for example with laparoscopic instruments. Coatings for Medical Devices One option medical device manufacturers often consider for adding functional value to medical devices is medical-grade PTFE. Although this type of coating is known for its low coefficient of friction, it is not recommended for high load applications because it is relatively soft and can wear away or experience micro-fracturing under high loads. Another alternative is anodization, an electrolytic process that coats the metal substrate. Unfortunately, it is impossible to effectively anodize stainless steel without losing wear resistance and durability, which is a significant disadvantage. Moreover, anodization can form a layer of rust on the stainless steel, causing it to corrode. For this reason, anodization is typically only used on aluminum or titanium. This limits the range of medical devices that can utilize this type of coating. Physical Vapor Deposition To overcome these challenges, medical device manufacturers are increasingly turning to physical vapor deposition (PVD), a process that describes a variety of vacuum deposition methods that can be used to produce extremely hard, thin coatings on stainless steel, titanium, ceramics and other advanced materials. These coatings provide a unique combination of extreme surface hardness, low friction coefficient and anti-corrosion properties. The coatings also have the advantage of being thin, typically 1-4 μm. This feature, in conjunction with close tolerancing, means that the component retains its form, fit and dimensions after coating without the need for re-machining. Introduced into the medical device industry nearly 20 years ago, PVD coatings like titanium nitride (TiN) are extremely hard (2,200 to 2,400 Vickers) coatings that provide excellent wear resistance. However, despite its functional properties the first medical instruments used the coating as a decorative, high-end finish. “Initially, the industry was looking for ways to differentiate instruments aesthetically and for identification purposes, and titanium nitride was as a solution for that. To this day, it is the highest volume PVD coating used in the medical device industry,” explains Matt Thompson, Business Development Manager in North America with Oerlikon Balzers, a company that has been producing specialized PVD coatings for more than 70 years. The company offers coating services at more than 140 coating centers worldwide, including 16 locations throughout the United States. Thompson adds that the orthopedic industry was the first medical segment to realize the functional strengths of PVD coatings, as applied to surgical instruments supplied with implants. The surgical instruments coated included items such as reamers, drills, taps and broaches. Given its widespread use, titanium nitride is well established in the medical device industry. This is supported by a vast quantity of literature and testing that supports the bio-compatibility of the coating, and many precedents with the FDA. As a result, other PVD coatings like diamond-like-carbon (DLC) and aluminum titanium nitride (AlTiN) have gained widespread acceptance – particularly for coating stainless steel. This is significant because there are few surface treatments that can be applied to stainless steel while still providing the desired functional properties. “DLC coatings provide an ideal combination of low coefficient of friction like PTFE, but with the hardness of a ceramic,” explains Thompson. “The coating has good functional properties, including excellent wear resistance, lubricity, corrosion resistance, anti-sticking and anti-fouling.” The DLC Coating even improves sharp edge retention of surgical instruments extending the service life of the instrument considerably. As an added benefit, cleaner cuts help surgical incisions heal more quickly, reducing patient recovery time. In addition to its low coefficient of friction and wear resistance, PVD coatings may eliminate the need for lubrication, functioning even under dry running conditions. This is particularly useful for the pneumatic components of powered instruments such as surgical bone saws or for the implantation and removal of intramedullary nails. Surgeons that must perform under the harsh glare of operating room lighting have also found PVD coatings useful for its anti-glare properties. For example, Oerlikon Balzers’ BALINIT®DLC Medical and BALINIT® C (a WC/C ductile carbide carbon of the DLC family) are black or dark grey, enabling surgeons to work faster and with greater comfort in bright operating rooms. Antimicrobial Properties Another important factor that device manufacturers must consider is whether the coating solution they choose contains antimicrobial properties. Invasive surgical instruments circumvent the body’s natural lines of defense. Therefore, it is critical that instruments’ surfaces are antimicrobial whenever possible to reduce the incidence of infection. Oerlikon Balzers’ titanium nitride (TiN-Ag) coatings, which are doped with silver and have a film thickness of approximately 2 μm, were specifically designed to address this issue and are one of the only types of coatings on today’s market to offer this antimicrobial protection. “Silver-doped titanium nitride is especially useful in trauma applications in which you’ve

Reinventing Commercial Fire Detection Reinventing Commercial Fire Detection Advanced technology enables greater fire safety by detecting smoke at the earliest possible stage, while improving aesthetics, reducing false alarms and maintenance Protecting life, property, and reputation is now much easier for commercial facilities ranging from hospitals, universities and indoor football practice fields to museums, cultural heritage sites, airport terminals, metro-rail tunnels/stations, and prisons as advanced aspirating smoke detector technology becomes widely available. The technology, which draws in air samples through flexible tubing to a central testing location, has been used for decades in sensitive applications such as cleanrooms and data centers where early smoke detection is critical. Compared to traditional spot smoke detectors, this approach dramatically improves commercial facility safety by detecting smoke at the earliest possible stage. It also significantly improves aesthetics with small, concealable sampling points, while reducing false alarms and even maintenance. As an example, one system, called the VESDA-E VEA, by Xtralis, a global provider of aspirating fire detection equipment, draws air through small, unobtrusive sample point in each room. The air is analyzed using sophisticated laser-based technology at the central unit to identify the presence of minute smoke particles in a continuous process. This approach offers earlier detection than even photoelectric technology detectors. The system is able to detect minor particles in the air much faster, even before a fire begins to flame and burn. In many cases, early warnings can speed evacuation and prevent fire spreading to other areas. As a multi-channel, addressable system, the VEA central unit can also pinpoint the exact location of the alarm. The use of multiple levels of alarm, set at specified concentrations of smoke, can also ensure time to investigate the alarms and make decisions. This facilitates safe evacuation and reduces the risk of unwanted sprinkler or suppression system release. Unlike unsightly traditional smoke detectors up to 7” in diameter, the VEA’s sampling points are about the size of a quarter, and can be concealed behind ventilation covers or within fixtures, making them inconspicuous to facility occupants and visitors. The aspirating approach is also much easier to maintain. Unlike traditional spot detectors which must be tested individually, and can be compromised by accumulation of dust and dirt, aspirating systems can self-clean and detect any blockages or breaks in the tubing. Such systems not only stop false alarms due to dust or dirt contamination of sensors, but also can distinguish between smoke, fire, and other airborne contaminants, which further reduces nuisance alarms. Mandated annual National Fire Protection Association (NFPA) inspections are also simplified. Unlike traditional smoke alarms, systems like the VEA do not require testing of each detector by introducing smoke directly into the chamber. Instead, the tests can be conducted at the central unit. A Host of Commercial Facility Applications While traditional spot smoke detectors have been common in commercial applications, a growing number of such facilities are successfully turning to aspirating detectors for a variety of reasons. Hospitals and Healthcare While spot smoke detectors are relatively easy to install, NFPA regulations mandate annual inspection and testing of each unit, which can be disruptive to patients, doctors, nurses and hospital personnel in a hospital and healthcare environment. This tedious, time-consuming process requires a fire alarm contractor to enter each room, introduce smoke directly into the detector and verify that it functions properly. For Jeremy Robison, Facilities Director/Safety Officer at Sonora Behavioral Health of Tucson, AZ, the annual inspections required significant planning. “For our patients, anything out of the ordinary, such as loud noises, can set them off,” Robison explains. In compliance with NFPA 72 Chapter 14 requirements, systems like VEA do not require the contractor to enter each room, which made Robison’s job easier. Instead, servicing and testing can be performed at the central unit and only takes a few seconds per sample point. In this way, the fire alarm contractor can complete the inspection at any time without having to move patients or access restricted areas. By some estimates, this can greatly reduce maintenance and inspection costs and reduce the total cost of ownership of the fire alarm system by up to 60%. Museums and Historical Structures To preserve the aesthetics of historic buildings like palaces and castles, while protecting lives and precious artifacts from fire, it is important to avoid the intrusion of bulky, traditional smoke detectors in every room. With this in mind, the Waterhouse Building in London, one of Britain’s most striking examples of Romanesque architecture and home to one of the most important natural history collections in the world, turned to aspirating technology. The small discreet detectors, in fact, can be hid behind light fittings, blended in with ceiling paintings, or form part of ceiling sculptures to provide virtually “invisible” smoke detection. “As one of the UK’s most popular museums, the Natural History Museum has a responsibility to ensure the safety of visitors and staff,” says Kevin Rellis, Head of Estates Projects. “Protecting against the risk of fire is key, and with VESDA we have ensured that we have the best possible coverage to safeguard the museum for generations to come.” Other heritage sites which rely on Xtralis include Hearst Castle in California; Finland National Art Gallery; Winchester Cathedral, St. James Palace, and House of Lords in England. Ultra-Modern Facilities At the other end of the spectrum, sleek modern facilities often feature minimalist architecture where bulky spot smoke detectors look strikingly out of place. As such, there is a premium on making smoke detection blend in with the surroundings instead of clash with it. A high-profile project for a new state of the art sports performance center at a prominent Pac 12 university required a smoke detector that was less obvious, even concealable, according to Bob Pritchard of Convergint Technologies, a company that designs, installs and services integrated building systems including electronic security, fire alarm and life safety systems. “The designers and the architects responsible for this remodel didn’t want to see any safety devices sticking out of the ceilings,” explains Pritchard. “It

Upgrading LED Hazard/Warning Strobe Lights: The Future is Now Upgrading LED Hazard/Warning Strobe Lights: The Future is Now LED technology reduces power consumption while increasing the brightness of hazard and warning lights used in construction vehicles, utility vehicles, snowplows, and tow trucks To ensure the visibility and safety of everyone on the road, the Society of Automotive Engineers (SAE) mandates that vehicles such as construction, utility, tow and snowplow trucks are equipped with hazard and warning lights. Whether roof-mounted beacons or directional surface mounted to the vehicle’s body or grill, these flashing strobe lights to capture the attention of motorists and pedestrians and warn of a potentially hazardous activity or situation. Available in several colors – amber, white and blue – and a variety of pulsating strobe effects, these lights come in several SAE classes and mounting styles depending on how quickly the vehicle will be moving. Now, however, as the lighting world continues to transition to LEDs, these hazard and warning lights are now available in low electrical consumption, long life models that far exceed traditional halogen or gas-discharge options. Making this move even more attractive for fleet managers are the plummeting prices of LED technology, which have decreased to the point that many vehicles that require Class 2 lights are instead being outfitted with brighter, Class 1 options given the minimal price differential. “Today, the entire hazard and warning light industry is undergoing a significant sea change – namely, the industry’s shift to LED technology,” says Chris Cammack of Grote Industries, a US-based manufacturer of vehicle lighting and safety systems for that has offered warning strobe lights for over 20 years, including an array of LED models. “The reason for this migration comes down to three factors: energy efficiency, longer service life, and brightness,” adds Cammack. “LEDs consume less power than any other lighting technology on the market and are powered by low voltage, allowing for minimal draw of electrical current from the vehicle’s battery.” By contrast, halogen lights draw an excessive amount of current, which can eventually lead to draining the vehicle’s battery. In addition, they are known for poor energy efficiency, with halogen lights losing as much as 95% of their energy to heat. Gas-discharge strobe lights are equally inefficient. However, unlike halogen lights it is not due to excessive current draw, but instead the intense and concentrated heat generated by the strobe, which can significantly shorten the service life of the flash tube. LEDs, on the other hand, consume only 25 – 35 percent of the power of gas-discharge strobe and halogen lights. As a result, LED strobe lights have a service life that is 10 times longer, often lasting 70,000 hours or more. With most of the world transitioning to LEDs, the quality has also continued to improve as well. In the early days of LEDs, they were not bright enough to meet SAE requirements for luminous intensity of hazard and warning lights, measured in candelas. However, technology has advanced and LEDs are now as bright – if not brighter – than the average strobe or halogen light. “LEDs today are much brighter,” says Cammack. “Today, they are more than bright enough to meet the SAE standard for candela over 100 feet.” Another barrier to early adoption was the initial price point, another aspect that has dramatically changed in the past decade, says Cammack. “The cost to upgrade to LED strobe lights was prohibitive, at least initially,” explains Cammack. “Fortunately, the prices have come down significantly in the past 10 years, and now they are about the same.” In fact, Cammack believes LED models will soon become less expensive as fewer manufacturers make models with outdated technology. Companies like Grote have phased out other technologies in favor of LED only. “Fewer companies are manufacturing gas-discharged strobe warning lights, so the price of those units is actually going up,” says Cammack. “In a couple of years, it will actually cost more for a gas-discharge or halogen strobe.” For manufacturers such as Grote, the options are virtually unlimited. The company offers Class 1-3 permanent, vacuum and magnetically mounted beacon lights in both regular and high profiles and a myriad of strobe patterns. Most of the company’s LED offerings only draw 0.4 – 0.35 amps at 12 VDC. The company also offers LED directional surface-mount strobes in 3, 6 and 12 diode options that feature 12 different selectable flash patterns in either of two phases, including “steady-on.” These too, require only about 0.1 amps per diode. 20, 30 and 40-inch LED “traffic directors” with 34 warning flash patterns and 5 phase options are also available, which are ideal for mounting on front push bumpers, pickup trucks, headache rack and running board lights. Cammack adds that it is important when upgrading to LED strobe lights to be cautious when purchasing inexpensive, imported products. Although they may be cheaper initially, some overseas suppliers utilize lower quality LED components. Moreover, it can become an issue of warranty claims arise. For more information, contact Grote at 2600 Lanier Drive, Madison, Indiana 47250; phone: +1 (800) 628-0809; e-mail: info@grote.com; or online at www.grote.com/warning-hazard/.

Maximizing the Car Wash Ticket With Professional Detailing Maximizing the Car Wash Ticket With Professional Detailing New systems are organizing equipment, personnel, and materials to dramatically enhance sales, productivity, and quality while minimizing waste For car washes looking to significantly boost their average ticket, detailing can be one of the most profitable add-on services today. Yet with the minimum wage rising and about 25% of the full serve budget and up to 10% of the flex serve budget dedicated to labor, operators need to reduce the cost of their labor and materials as much as possible in the available space. The problem is that for too long traditional car wash detailing has been surprisingly inefficient, utilizing non-standardized, even messy approaches that not only waste labor, time and materials, but also “scare off” customers. Now, however, top car wash owners are taking a page from the auto industry’s lean production techniques. By adding professional detailing systems in a compact footprint, they are managing equipment, personnel, and materials to optimize productivity, workflow, and quality while also minimizing waste. With this approach, they can cut 25% or more of the time and labor needed, and save several dollars per vehicle in chemical and material costs for approximately a 1-year ROI. “With our new detailing system, we are able to charge about 30 to 40% more per car while getting more referrals and repeat business,” says Chris Skoglund, owner of Skogie’s Auto Spa in Kelowna, BC, Canada. “Our revenue from two detailing bays is 25% higher than we anticipated, up to $250,000 [Canadian] a year.” Traditional Detailing Inefficiencies The challenge is that the quality of traditional detailing is often poor due to a lack of a standardized process, materials and management. Most detailing operations store equipment, supplies and chemicals in a disorganized manner and inadequately control the process. Yet when the operation is a mess, customers are hesitant to trust their vehicles to detailers who cannot keep their own operation clean and presentable. Spray bottles, chemicals, buffers, pads, and materials may be in different locations, requiring detailers to leave the service bay to retrieve the items before work can proceed. The detailing steps may be followed, but often not in a systematic order. Furthermore, the process is usually inconsistent, with chemical concentrations varying depending on how much of each chemical is put into the bottle and who is diluting it. Too much time is wasted filling bottles, mixing chemicals, looking for this, and waiting for that. Chemical and supply costs also increase due to spills and theft in such operations. According to Skoglund, when Skogie’s Auto Spa had previously been a full serve wash, its add-on detailing service needed greater throughput, consistency, and quality control. “We had one guy doing the detailing in the parking lot, so he had to run around to get supplies as well as mix and fill spray bottles,” says Skoglund. “We spelled out chemical mixing directions for our staff, but over time these weren’t followed so we’d get uneven mixtures. The detailing was inconsistent and not really professional because we didn’t have a system in place.” Greater Control Improves Productivity and Quality Following the lead of the auto industry’s implementation of lean production, popularized by the Toyota Production System, top auto dealers are now learning how to cut the waste from their detailing operations while optimizing workflow, quality, turnaround, and customer value. This is turning underperforming detail operations into significant revenue sources. What this approach requires is organizing and controlling the detailing process via centralized stations that anticipate every need and put it all at the fingertips of the person doing the work. This includes the organization of materials at fully supplied workstations with controlled chemical delivery and dilution, along with racks and carts. One example of this approach involves the use of ChemSpense workstations by Detail Plus Car Appearance Systems, a Portland, Oregon based manufacturer of car detailing equipment. The system puts all the tools and supplies needed by detailers within easy reach so they never have to leave the vehicle or service bay. The workstations are placed on both sides of the vehicle to allow multiple technicians to work independently at once. This increases productivity so more vehicles are detailed per day. When Skogie’s Auto Spa expanded to include an automatic tunnel wash, self serve bay barn, and flex serve area, Skoglund also set up a two service bay detailing shop, which includes several ChemSpense workstations along with a variety of other equipment. The workstations dispense up to 12 necessary cleaners, shampoos, and treatments through color coded, chemical lines, eliminating the waste, distraction, and mess of squeeze and spray bottles. The system also dispenses more viscous chemicals, such as waxes, polishes, and compounds, which further expedites paint finishing. “With the Detail Plus workstations, all the equipment and supplies are right there within easy reach,” says Skoglund. “We often have two technicians detail a car together so customers don’t have to wait. We detail faster with more consistency and professionalism. Now detailing is one of the most profitable areas of our business.” Because each workstation includes a powerful wet/dry vacuum, this eliminates the need for clumsy portable shop vacuums, which are prone to bump into and mar vehicles when dragged around the shop. For cleaning and shampooing carpets and fabric upholstery, each workstation also has an internal heated soil extraction system. Two coiled air lines are available for operating pneumatic tools such as buffers, shampooers, and orbital waxers as well. One key to making the system function more productively than shops using spray bottles is an accompanying Chemical Dilution and Dispensing System. This automatically dilutes all water-based chemicals to exact proportions, which improves safety and quality while eliminating chemical waste and improper mixing. All chemicals, including ready-to-use products, are delivered to the workstations installed in the detailing center. “The chemical distribution center helps ensure detailing quality and consistency by eliminating improper chemical mixing,” says Skoglund. “It makes it easier to train employees as well. We know that

Semi-Truck OEMs Begin Switch to LED Headlights on New Models Semi-Truck OEMs Begin Switch to LED Headlights on New Models Starting in 2019, LEDs to replace halogens and HIDs on most new class 7 and 8 trucks For drivers of semi-trucks, driving at night or in bad weather is about to become significantly safer as most class 7 and 8 truck OEMs are finally making the switch to LED headlights beginning with 2019 year models. Although most trucks come installed with halogen or high-intensity discharge (HID) headlamps today, the declining cost of LEDs combined with a host of safety, maintenance, and operational benefits has pushed OEMs to make such headlights standard in upcoming models. However, instead of relying on LED technology adapted from the private car sector – which may not always be suitable for over-the-road trucks – OEMs are partnering with lighting manufacturers that specialize in commercial truck headlight applications to optimize safety, function, and even aesthetics. Why LED Headlamps Now LEDs have long been used in the heavy-duty trucking aftermarket and for OEM applications such as clearance/marker lights, cab lights, stop tail turn lights, back-up lights, turn signals, auxiliary interior lighting, and even commercial truck headlights. However, due primarily to a higher initial cost, OEMs have resisted making LEDs standard as headlights. Now, with the price of LEDs dropping – along with key improvements in the technology – OEMs are now ready to take the lead. By offering LED headlights as a standard feature, commercial fleets and owner-operators no longer have to worry about aftermarket LED headlight replacement kits, which may not always meet Department of Transportation (DOT) code. The Benefits of LED Headlights Because the color of LEDs is closer to that of daylight than the yellowish hue of halogens, it appears brighter and can illuminate details of objects in the distance better. They also help a driver see more at the edge of the road, where traditional lamps tend to fade out even on high beam. This improves safety and reduces eyestrain since it helps the driver more quickly and easily spot vehicles, pedestrians, signage, road conditions, and wildlife to prevent potential collisions and driving errors. Since LED headlights can last 30,000 hours, about ten years of service for a commercial over-the-road truck, they can also dramatically reduce the risk and cost of unscheduled downtime to service failed headlights, as well as cut down on the number of fines and points against the driver and the fleet’s CSA scores if cited by law enforcement. Although LED replacement kits have been available, some may not be DOT approved. Replacement bulb kits designed to convert halogen lamps to LED must be marked with the DOT symbol. However, some of the kits do not meet the standards for beam pattern, when placed in a reflector designed for a halogen bulb. Why Heavy Truck Specific LED Headlamps Because typical cars and over-the-road heavy duty trucks are so different in size, shape, configuration and use, LED headlamps need to be specifically designed for class 7 and 8 trucks, and not come from headlamp manufacturers trying to adapt a passenger car design to satisfy truck requirements. “Long haul trucks on the road may need an LED reflector pattern that reflects light farther out to allow adequate reaction time and braking distance while traveling at higher speed,” says Jessil Joseph, of Grote Industries, a manufacturer and supplier of LED lights and lighting products for heavy duty trucks. “Short haul trucks, which travel more in urban areas, usually need a wider beam pattern that can better detect traffic, cyclists, and pedestrians which may unexpectedly cross in front of the truck.” In this regard, OEMs can benefit from partnering with LED light manufacturers that can customize to the specific needs of the commercial trucking industry. For example, Grote is currently working with leading OEMs to customize headlight beam pattern and performance characteristics. Besides allowing a longer distance or wider beam, the company can also match the high beam and the low beam to prevent overlap or a “dead” area. This can enhance nighttime and bad weather visibility while reducing driver fatigue. Using a combination of reflectors with the LED source, Grote is also achieving energy performance efficiencies of up to 70% compared to a typical 40% industry standard. As such, more efficiency translates into less heat, a smaller lamp profile, and a more aesthetic, streamlined design. “More heavy duty truck OEMs are also looking for custom headlamps to differentiate their brands, as well as satisfy the requests of fleet managers and owner-operators who want a distinctive look,” says Joseph. Whether a driver, fleet manager or an owner-operator seeking to improve safety, operational costs or aesthetics, heavy duty truck OEMs will have them covered when they begin to roll out new models with the latest LED headlights customized to their unique requirements. For more information, contact Grote at 2600 Lanier Drive, Madison, Indiana 47250; phone: +1 (800) 628-0809; e-mail: info@grote.com; or online at www.grote.com.

Withstanding Extreme Wear in Bulk Material Handling Equipment Withstanding Extreme Wear in Bulk Material Handling Equipment Urethane provides greater wear resistance than steel or rubber, with better cleanability, and can be customized to meet individual specifications Bulk material handling equipment for rock, stone, aggregate, gravel, and sand can experience extreme wear, whether for mines, quarries, or plants for concrete batching or highway and construction material processing. The handling equipment – such as batchers, bins, chutes, drums, hoppers, turn-heads, dump cones, belt cleaners and skirting – can experience severe wear in contact with a variety of coarse materials, particularly at “hot spots” where excessive abrasion occurs. In such cases, the bare structure of the equipment may not be adequately wear resistant and even traditional steel or rubber protective liners may insufficiently control the abrasion. This can pose a risk of costly spillage through holes and gaps, along with production downtime for repair and clean up. For such applications, sheets made from urethane (short for polyurethane) provide far better wear resistance than more traditional options such as rubber or steel (both AR400 and AR450 plate). Urethanes are cost-effective, dependable elastomers that combine some of the performance advantages of high-tech metals, ceramics, and plastics, along with the resiliency of rubber. Because urethanes also offer significantly less friction than rubber, this not only helps to reduce wear in contact with rough materials like aggregate and sand, but also improves equipment cleanability between wet batches, which enhances productivity. Now this “tougher than steel” liner can be made even more durable with embedded ceramic tiles. It can also be cut from full sheets of various sizes to fit the contours and shapes of high contact areas, so it can easily be welded or bolted to provide extreme wear protection wherever it is required. While such liners can be cut to fit and installed onsite, custom liners made to fit more complex configurations can increase reliability, simplify installation, and further reduce production downtime. Extreme Wear Resistance The outstanding abrasion resistance of urethane elastomers has led to many important bulk material handling applications. “In plants that handle bulk materials, like concrete ready mix facilities, where severe wear is a problem, special urethane formulations like Kryptane can last several times longer than steel or rubber, which reduces production downtime, replacement cost, and labor for change out,” says Jesse Roberge, a concrete industry product specialist at Argonics, one of the U.S.’s largest producers of wear resistant urethane products. Kryptane, an extremely wear-resistant material designed by the company for applications where abrasion, sliding, or impact occurs regularly, is often used in a wide range of batch plant applications including as drum, chute, bin, hopper, and conveyor liners. According to Roberge, different applications require different thicknesses of urethane. “For wet batch central mix drums, we recommend a 1” thick liner, which can last 5 to 10 years,” says Roberge. “In fact, some wear liner manufacturers offer a warranty of several years or based on the yardage put through a drum.” Some other common thicknesses of urethane for wear liners include: ½” for an aggregate batcher or aggregate bin/hopper; and ¾” for a dump cone/directional hopper. To most effectively control extreme wear, such as for feed chutes, discharge chutes, and turn-heads, Roberge recommends the use of liners that actually embed ceramics into the urethane. “Urethane with embedded ceramics can be optimized to resist not only sliding abrasion, but also impact, or various combinations of the two,” says Roberge. “This approach can last up to 10 times longer than steel or rubber alone, and up to 4 times longer than urethane alone.” To resist liner degradation in hot, humid climates and further extend liner life, he also advises the use of an ether urethane formulation, instead of a typical ester formulation. Roberge points to another benefit of the urethane. Compared to steel liners, the urethane significantly reduces the noise level at the concrete plant. “When all this rock and aggregate falls onto metal, it can be quite loud, particularly if it is in an enclosed building,” he says. “Because the urethane has natural resilience, it deadens the sound quite a bit and makes conversation easier.” In simple batch plant applications, cutting and self-installation of the wear liners can be done. Standard sheet sizes are 4’x8’, 4’x10’, 5’x8’ and 5’x10’, in thicknesses from 3/16” to 1”; rolls are also available – 4’x25’ up to 5’x100’. The material can be installed/fastened using a weld-in or bolt in technique. Modular panels, in urethane and urethane with embedded tiles, are also available in 12’x12’ and 12’x18’ sizes in a variety of thicknesses. These can be quickly welded or bolted in to manage certain common “hot spot” repairs, such as in screen feeders and discharge lips. Custom liners, however, are commonly used by the customers of bulk material handling plant equipment, and anywhere that standard sheets do not fit, where size and weight are a concern, or where a long-term wear solution is needed. “When custom liners are cut to an exact size or pre-molded to fit right into the equipment, it eliminates wasted material and the need to cut and trim onsite,” says Roberge. “Because such pieces are manufactured to fit precisely together, they install quickly with minimal production downtime. They are also easy to replace a piece at a time as needed.” The process for customizing liners is quite simple for plant managers and the OEMs that manufacture such equipment. According to Roberge, the customer typically provides a sketch, drawing, or photo of the bulk handling equipment to be lined, along with dimensions and notes. The wear liner producer then finishes the drawings and provides a quote. If the customer approves, the liner is completed, shipped, and is ready for installation when received. Whether used as standard or custom liners, urethane’s extreme wear resistance can offer plant operators, design engineers and equipment manufacturers extended equipment life and trouble-free handling of bulk aggregate and sand materials. This improves safety, production, and the bottom line. For more information contact Argonics, Inc., 520 9th St., Gwinn, MI

Planar Honing: Planar Honing: Producing a Fine Finish on Flat Surfaces For years the flexible, ball-style hone has dominated the market for applications that require honing of cylindrical metal surfaces such as engine piston bores and drilled through-holes. Now the tool, in a slightly different configuration but with the same filaments and abrasive globules, is increasingly being utilized on two-dimensional, or planar, surfaces. This is opening up possibilities for applications in which hardened metals interact or mate in surface-to-surface friction with other metals or materials. Examples include sliding guideways, flywheels, brake rotors and others. “The same type of surface we have promoted and produced for years for internal cylinders also has validity for flat surfaces,” says Jonathan Borden, National Sales Manager of Brush Research Manufacturing. The abrasive technology company is known for inventing the Flex-Hone Tool and turning it into a global brand. Known widely as a tool used for de-burring, plateau honing and deglazing, the Flex-Hone is a highly versatile tool used for a variety of machining operations. Somewhat resembling a spinning bottlebrush, this tool is characterized by abrasive globules that are permanently mounted to flexible filaments that are attached to a center shaft. This extremely flexible, low-cost tool can be used for sophisticated surfacing, de-burring, edge-blending and cleaning. In the automotive industry, for example, cylinder hones are often utilized for creating an effective surface finish on engine cylinders. Engine cylinders have surface-to-surface contact with pistons sliding against the wall. To reduce power losses from friction, engine cylinders are honed so piston rings can seat properly as well as to allow for lubrication flow and oil retention on the walls of the cylinder. According to Borden, the principles behind cylinder honing apply also to flat, or planar, surfaces. Borden says the process was recently put the test for sliding guideways, a critical structural component of CNC machines. These guideways provide the smooth, linear motion of the machine tools along its predetermined path. It is therefore fundamental to the accuracy and precision that can be achieved with this type of equipment. The goal of the study was to establish if Cubic Boron Nitride (CBN) milling tools followed by a secondary planar honing operation could replace the traditional grinding process used to manufacture the hardened cast iron guideways. The experiment and subsequent conclusions were outlined in a published article in the Journal of Manufacturing Science and Engineering, July 2017 issue. The article, entitled “Optimization of Planar Honing Process for Surface Finish of Machine Tool Sliding Guideways” was authored by Kory Chang and Masakazu Soshi of the Advanced Research for Manufacturing Systems (ARMS) Laboratory in the Department of Mechanical and Aerospace Engineering at the University of California, Davis. As the foundation for linear motion, the surface finish on sliding guideways is a critical factor. A poor surface finish can shorten CNC tool life, increase power consumption and cause errors in tool position, resulting in out of tolerance workpieces. However, the traditional grinding process for manufacturing sliding guideways involves removing, cleaning, and then repositioning parts several times. The hardened surfaces, which measure as high as 50-60 on the Rockwell C Scale, also require grinding because milling cutters typically wear out too quickly. Instead, an alternative utilizing Cubic Boron Nitride (CBN) milling tools along with a secondary planar honing operation was proposed in the design experiment. CBN is one of the hardest known materials for machining of steels and cast iron. Unfortunately, the milling process does not create a consistent surface finish. For that, planar honing would be used within the same machining center. According to the study, the Flex-Hone for Rotors from Brush Research Manufacturing was selected as the tool for the research. The planar honing tool provides a low-temperature abrading process that exposes the undisturbed base metal. Unlike the “bottlebrush” design used to hone cylinders, the planar honing tool utilizes the same type of filaments with abrasive globules mounted to a disc. The tool can be held in a collet, chuck, or similar holding device. To achieve the optimal finish, a 400 and 600-grit silicon carbide Flex-Hone for Rotors was selected after it was determined that a fine grain size was all that was required to flatten and create the plateau peaks on the cast iron sliding guideways. The Flex-Hone tool, along with other factors such as pressure, spindle speed, feed rate and number of strokes, was expected to produce a surface finish in the 0.3–0.6 µm and 0.2–0.3 µm were the respective Ra range. The experiment study concluded that the “analysis showed that the ideal plateau finish desired on the hardened cast iron was supported by both measured real parameters and the Abbott–Firestone curve.” According to Borden, sliding guideways is only one example of the type of surfaces that could benefit from planar honing. “Others applications that have already benefitted from this type of hone include automotive and motorcycle disc brake rotors, fly wheels and clutch plates,” says Borden.  For more information, contact Brush Research Manufacturing, Brush Research Mfg. Co., Inc., 4642 Floral Drive, Los Angeles, CA 90022; Phone: (323) 261-2193; Fax: (323) 268-6587; email: info@brushresearch.com or visit the web site: www.brushresearch.com

Tooling Up for OEM Success Tooling Up for OEM Success Tooling decisions, which play a major role in the cost per part and turnaround time, can be optimized by collaborating with a flexible metalworking supplier OEMs that outsource metal parts to contract manufacturers must often guess at the immediate production requirements for new products, so initial forecasts are often conservative or – the complete opposite – unrealistically high. With this inevitable uncertainty, OEMs are also hesitant to invest significant dollars in hard tooling, which can cost tens of thousands of dollars upfront. Instead, less expensive soft tooling options are often selected, even if it increases the price-per-part initially. However, as production demands increase, soft tooling options can quickly slow production. At the appropriate “tipping point” in demand, OEMs ideally should transition to hard tooling, hybrid approaches and even progressive dies that speed turnaround time and drive down the price. This “laddering up” of the range of tooling options requires assessing at each plateau whether or not greater upfront investment in tooling will pay off with a relatively quick ROI. Since tooling plays such a key role in this equation, it also means working closely with OEMs willing to evaluate the best available tooling options at any time as production requirements increase. “As production requirements increase, transitioning to a more efficient type of tooling can save some OEMs tens of thousands of dollars a year with a ROI measured in weeks or a few months,” says Bob Denholtz, president of DureX Inc., an ISO 9001 registered contract metal fabrication facility based in New Jersey. “Any good metal parts supplier should be able to help the OEM determine the most cost-effective tooling for their situation.” Although, tool selection involves various factors, including part size, metal thickness, complexity, and finish, the cost per part is often related to the type of tooling utilized, says Denholtz. This progression generally ranges from soft tooling to hard tooling, hybrid approaches, staged tooling, and fully progressive dies. Soft Tooling Low volume part manufacturing often involves soft tooling for sheet metal fabrication. Usually this entails having a flat part or a slightly formed part getting holes, slots, or tabs punched in it by a CNC laser or turret punch press before going to a press brake and getting bent to the proper angle. “Soft tooling typically costs $75 to $500, but can cost up to $2,000-3,000 for more complex parts,” says Denholtz. “This can work for prototyping and low volume production orders. However, it can take several minutes of machine time to make each part, depending on its complexity, so the cost per part is higher.” One strategy to lower or even eliminate soft tooling cost is to borrow the tooling from a supplier’s “library of tools.” Because DureX has been serving a variety of markets for over 30 years, they have built up an impressive inventory of soft tools in many sizes and shapes. When appropriate, these tools can be put back in service. When that is the case, DureX does not charge for the item. “Suppliers with a wide range of experience have the most soft tools in their inventory, so may charge nothing or a discounted rate for a tool in their library,” says Denholtz. “Those contract parts manufacturers that only serve specific industries will generally have to charge for new soft tools.” Hard Tooling When production volumes increase to 15,000 or more parts annually, OEMs often benefit from moving from soft tooling to hard tooling to reduce costs. According to Denholtz, the cost of hard tooling can vary from $5,000 to $300,000 or more depending on its size, complexity, and whether it is designed to produce finished parts. “When one OEM gave us a power supply chassis and cover to produce, they started at 500 parts per month with soft tooling,” says Denholtz. “However, when production requirements increased to 4,000 parts a month, we suggested they move to hard tooling to reduce the price from $22 to $15 a part. With a hard tooling cost of about $85,000, they achieved ROI in about four months.” Unlike soft tools, hard tools are not available in a contract manufacturer’s “library” as they are built to produce that specific product so each must be purchased. Still, there are ways to keep costs down including using the same hard tooling for a “family” of products. Hybrid Tooling As the name implies, hybrid tooling is a combination of soft and hard tooling. Depending on the part, it might begin as a flat piece of metal that is punched or formed with a soft tool, with further forming by a hard tool. For example, a metal office ceiling fixture could start in a turret that punches all the holes and slots before it is moved to a hard die that forms up the sides into a box in one operation. “So instead of putting a flat piece of metal in a brake and hitting it four times to bend the two sides and two ends, I could use a die and hit it once. So it only takes 30 seconds or less to make the entire part instead of 2 minutes,” explains Denholtz. Staged Tooling To create metal parts at even greater speed and volume as well as lower price per part, staged tooling can be used. This basically involves moving a metal part between two high performance dies, so the work is performed in two distinct processes that utilize hard tooling. “Instead of taking 5 minutes in a machine to punch all the needed holes individually using a soft tool, I could make a blanking die and punch everything in one shot in 5 seconds,” says Denholtz. “Then I could put it in a box form and form it into shape in another 5-10 seconds.” Progressive Dies The fastest, highest volume part production can be achieved by a progressive die. This accomplishes multiple operations in a single process using hard tooling. Depending on the part, a progressive die utilizes

Acquiring Complex Machined Parts in the “No Bid Zone” Acquiring Complex Machined Parts in the “No Bid Zone” Pharmaceutical companies are partnering with machine shops capable of producing ultra-high tolerance parts for enhanced reliability To safely produce reliable, life saving drugs with consistent dosing, the pharmaceutical industry often requires machined parts of exceptionally high tolerance and complexity within its production equipment. The difficulty is that most machine shops – even high precision operations – typically machine parts down to .001” tolerance. However, when ultra-high tolerance parts (up to .0001”) are required, a significant number suddenly enter the “no bid zone” where contract part manufacturers pass on jobs that are too difficult or beyond their capability. “Many machine shops will not bid on an ultra-high tolerance part because they are concerned about the amount of time and effort it will take to meet the required tolerances,” says one longtime engineering manager at a pharmaceutical company that designs and builds its own equipment for filling and packaging. “The fact is that [in the pharmaceutical industry] a part that is 99% ‘right’ may not be good enough,” he adds. “For one job, we sent some ultra-high tolerance work to a machine shop and they made about 30 parts, but we had to reject them because they failed independent third party measurement and functional testing.” Fortunately for pharmaceutical equipment manufacturers with complex components in the “no bid zone,” there are machine shops capable of producing ultra-high tolerance parts consistently. When they do, it is not usually a matter of having superior CNC equipment, but rather a combination of experience along with a knowledge of unique challenges of machining and inspection required to hit the mark every time. Overcoming Precision Machining Challenges When pharmaceutical production equipment is used to handle, mix, process, and package medications in precise quantities, the CNC machining of the component parts must also be excruciatingly precise. This includes parts with tolerances down to .0005” and sometimes less, machined out of 316 Stainless or exotic metals such as titanium, Invar, Kovar, and Nitronic 60. However, an increasing number also want high tolerance parts that are made out of ceramics and plastics like PEEK. To avoid the substantial downside of dealing with failed parts, pharmaceutical engineers send higher tolerance work to machine shops with proven background handling such items. One example is Newark, CA-based Silicon Valley Machining (SVM), a shop that has specialized in ultra-high tolerance precision CNC milling and turning services as well as CNC 5-Axis prototype manufacturing since 1997. While the company offers services from prototyping to high volume, “lights out” manufacturing, its focus on consistently holding extremely high tolerances down to +/-0.0001” is typically the reason pharmaceutical equipment manufacturers seek them out. “We go to SVM because they will machine really difficult parts that many other firms will turn down and not even bid,” says the engineering manager. “This includes both round and tapered parts with tolerances in the range of .0001” to .0002”. “It can be tough to match such high tolerances in every way because in every component there could be 100 dimensions that all must be near perfect,” he says. “SVM is able to make highly precise parts that match the print.” Success in the “No Bid” Zone To achieve extremely high tolerances, machine shops must pay attention to minute details and factors that go well beyond what even “precision” parts require. SVM owner Mark Serpa says that really begins with a mentality amongst the employees that “no part is too complex to figure out.” “We can hire extremely experienced people or train employees, but if they do not have the right mindset, no years of experience helps because these type of parts cannot be machined like ‘all other parts,’” adds Serpa. “It requires a team of different personalities, education, experience and age levels working together. That makes a huge difference.” To ensure that ultra-precise tolerances are achieved on every part, state-of-the-art quality control systems must also be in place. In the case of SVM, the company’s measuring equipment includes a Zeiss Contura G2 with scanning coordinate measuring machine (CMM) capability for inspection down to 0.00005”, a MicroVu Vision System with 575x magnification and a Starret 14” Digital Comparator with 50x magnification. Serpa says ultra-high levels of precision may even dictate that the same style and brand of inspection equipment be used on both ends. “To enhance reliability and ensure an ‘apples to apples’ comparison, we have even had to purchase inspection equipment that matches what our customer uses in their facility,” says Serpa. Even the way each part is handled and moved from point to point can affect how accurately it is measured. “You have to think about where the part sits and how it is handled,” adds Serpa. “You have to think about how it is moved from machine to machine, from person to person, because all of these factors can affect measurement when tolerances are that extreme.” In some cases, a short period of time may even be required so parts can acclimatize to a new environment. “Different types of materials expand or contract with temperature at different rates. This must be accounted for when extreme tolerances are required,” says Serpa. “You cannot simply grab a part off a shipping shelf and test it or you may get a different result.” When ultra-high tolerances are involved, the role of quality control (QC) personnel must also shift from simply assessing pass/fail of parts to “engineering support.” “QC inspectors have to not only tell the machinist if the part is to print or not, but work with them to solve issues in manufacturing that are contributing to the parts not passing,” explains Serpa. “This is not the standard mentality in the industry; it is a different skillset, level of work and responsibility,” explains Serpa. Pharmaceutical Hygiene Since the pharmaceutical industry must maintain safety at all stages of production, the hygiene and cleanliness of production equipment components is a top priority. In another example from the

Excelling in Today’s Challenging Global Steel Marketplace Excelling in Today’s Challenging Global Steel Marketplace How POSCO is addressing market obstacles and protecting its vital steel production assets from corrosion After the global steel industry’s recent downturn, caused by oversupply, low prices, and rising raw material costs, Pohang, South Korea based POSCO, one of the world’s largest multinational steel manufacturers, needed a strategy for handling such challenges while continuing to protect their assets and remaining industry innovators. By focusing on high value-added products, reducing cost, and innovating its product and process POSCO posted a double-digit operating margin and a jump in stock price of over 50 percent in 2016, according to its annual report. Now the company – which won the world’s most competitive steelmaker competition for the eighth consecutive year in 2017, as announced by World Steel Dynamics (WSD), the world’s leading steel industry analysis agency – is poised to make further gains with innovative products and processes that will transform the industry. One key initiative POSCO is pursuing involves a unique approach to protecting its massive carbon steel production and infrastructure assets from corrosion. This is a continual challenge for steel manufacturers globally, particularly along coastline exposed to high humidity and salty air. The company is utilizing an innovative coating that provides a long-term solution to fighting atmospheric corrosion and corrosion under insulation (CUI). The coating not only helps to minimize required maintenance and production downtime, but also promotes environmental health and safety, which is one of the company’s key missions. Protecting Critical Steel Assets from Corrosion Because steel mills require sufficient raw product in order to produce, they are often located near marine terminals where both raw material and finished product can be easily shipped. As such, steel mill processing equipment and infrastructure must be coated to withstand atmospheric corrosion from the high humidity and salty air. It must also resist corrosion under insulation (CUI), which can result from exposure to moisture from sources such as steam, wash downs, sprinkler systems, or frequent condensation and evaporation of atmospheric moisture. However, when traditional barrier type coatings are commonly reapplied every few years in such coastal areas, this can increase maintenance cost and production downtime. To protect its steel assets from corrosion for decades, as well as improve environmental health and safety, POSCO turned to EonCoat, a spray applied inorganic coating from the Raleigh, North Carolina-based company of the same name. EonCoat provides two layers of protection for POSCO’s steel assets. First, unlike conventional barrier coatings that only physically cover the surface, it forms an alloy layer that chemically bonds with the surface of the steel. This effectively prevents intrusion from moisture and other corrosion promoters. EonCoat also forms a ceramic outer layer that further resists corrosion, water, abrasion, impact, chemicals, and high temperatures. According to Sungjun Ahn, Senior Manager from Dong Buk Chemical, the company in charge of the application process at POSCO, EonCoat was selected to extend equipment life in accord with POSCO’s sustainability and environmental management policies. “POSCO stakeholders benefit, including investors, when they can safely extend the lifespan of their steel assets with less maintenance,” says Ahn. “Without frequent repainting, they can more productively invest in further product and process innovation.” At the Pohang steel plant, the spray applied inorganic coating is being used to protect a variety of equipment such as storage tanks, boiler dust collectors, and dock pilings (including the splash zone and below the waterline). Due to the coating’s high temperature resistance of up to 500 Celsius, it is also being used in high temperature areas of the steel making process, such as at the ends of steel rollers and for pipeline insulation. Because of the coating’s unique inorganic properties, it is very effective at stopping CUI, which can affect pipeline or vessels beneath insulation due to water penetration. Since the coating is also chemical resistant, it is also being considered as a primer for equipment in contact with sulfur dioxide (SOx) and nitrogen dioxide (NOx) gasses, which result from burning fossil fuels and smelting mineral ores. More Innovative Processes While taking a proactive approach toward preventing corrosion, POSCO utilizes a number of advanced steel producing technologies at its two South Korean steel mills, in Pohang and Gwangyang, including: Finex: This eco-friendly iron making process allows the direct use of cheap iron ore fines and non-coking coal as feedstock. Compared to a traditional blast furnace process, this significantly lowers operating cost and emissions as well as dramatically reduces overall construction costs by eliminating the need for sinter and coke plants. Strip Casting: This method eliminates the slab-making process to produce hot-rolled flat products directly from molten iron. Compared to traditional slab-making, this technique reduces cost, energy use, and production time as well as pollution. Endless Hot Rolling: This solid state joining method is a rolling technology that joins bars made from slabs, the material for hot-rolled products, for endless rolling. Compared to previous rolling processes, this method drastically cuts production time while economically offering firmer, thinner steel plates. Game Changing Products With such advanced steel producing technologies in place, supported by a preventative approach toward corrosion, the company has recently introduced some important product innovations. This includes super-high-strength “Giga Steel” – which can withstand more than 100 kg of load per 1 mm2 with a tensile strength of 1.5 Giga – produced at its Gwangyang Steel Mill in Korea. Since the tensile strength, measured by pulling the steel plate from both ends until it is torn, is greater than 1 gigapascal (GPa), a unit of force, it was dubbed Giga Steel. As such, a palm-sized (10 cm X 15 cm) piece of Giga Steel can support the weight of 1,500 1-ton semi-mid-sized cars. The unique material will enable building significantly lighter, stronger vehicles since it is over three times stronger than aluminum and has excellent formability. At the company’s Global R&D Center in Songdo, Korea a new Steel Forming Laboratory will evaluate the formability of newly developed steel products such as the Giga

Damage Free Sign Labels for Hospitals and Research Labs Damage Free Sign Labels for Hospitals and Research Labs Customizable sign labels – printed with laser or ink jet printers in minutes for vital interim life safety measures – can be removed cleanly from most surfaces, reducing repair and repainting Throughout hospitals and research labs, signs are used virtually everywhere from the front door and patient rooms, to the OR and ER, to research and test areas, to the routes and maps for emergency exits. Signs are used in many ways, whether informal, formal, or mandated by law, and vital interim life safety signage can often be required. Permanent signs may not be an option when the information changes and needs to be updated. This can occur when policies and procedures change or during community events, such as volunteer orientation and open houses. “In hospitals, temporary signs are used for directional navigation, identifying rooms and escape routes, as well as to provide warnings and precautions about various hazards,” says M. Geary, an EHS manager at a university hospital. “This is particularly important when any construction, remodeling, or refurbishing is occurring.” Safety notifications, including emergency contacts and potential hazards may also change frequently in research labs, particularly at universities where these may change as often as every semester when new projects may commence. In such temporary situations, the traditional signage options for administrators and facility managers are limited. Because signs can be located in high traffic areas and subjected to harsh cleansers, the sheets of paper, cardstock, sheet protectors, laminated sheets, and posters used must not only present a professional image, but also stand up to the environment and even meet specific safety codes. This is where the problem lies. Since many signs are not designed for high traffic use, they may not look professional or be resistant to wear and tear from frequent touching, handling, or the cleansers used in such environments. As a result, they are damaged easily and must be replaced frequently. Many signs can also cause considerable damage to the underlying surfaces when taped, tacked, nailed or screwed to walls, glass, or equipment, which can hasten the need for costly repair and repainting. Sign removal can also leave behind unsightly residual tape or adhesive. This is exacerbated when signs include information that is routinely changed or updated. With premature facility repair and wall repainting costing hospitals and large research labs thousands of dollars in annual maintenance, the ideal solution would be signage that is easy to install, durable enough to endure harsh conditions, yet comes off easily when necessary, leaving no trace. This can significantly reduce the need for facility maintenance, freeing up resources for higher priority purposes. “Commercial-grade labels used as signage must be more durable than those used in a lower use area, but also should remove cleanly when they need to come down,” says Tina Huff, Group Product Manager at Avery Products Corporation. “For us, the key to accomplishing this was developing an adhesive that holds well but can be removed when needed. Achieving that balance is harder than it sounds.” As a result, Avery created Surface Safe Sign Labels – an exclusive, proprietary product specially engineered to stick securely yet remove cleanly without damage or residue from painted walls, doors, windows, furnishings, equipment, and other interior surfaces. These “labels used as signs” are made of durable, commercial-grade material that resists water, chemicals and even abrasion. Available in a variety of sizes, they print easily on standard laser or inkjet printers, opening a world of possibilities for custom, do-it-yourself signs. Unlike standard office labels with a paper substrate, the topcoat of the commercial-grade sign labels is waterproof and chemical resistant, while its polyester substrate is a durable, scuff and tear-resistant film. These qualities are ideal for safety-related signage mandated by regulation or required by administrative policy. “We do a lot of interim evacuation routes in our hospital and have to post temporary signs along these routes,” says Geary. “Whenever you change exit routes, due to construction or other reasons, you have to train staff and post appropriate signage identifying the new routes. The removable Surface Safe sign labels are perfect for this. They are also useful in the clinics as door postings to notify personnel to take necessary precautions, such as when a patient is TB positive.” Such removable signage is also helpful in meeting required standards at a reasonable cost for temporary projects. “We are able to create customized ANSI standard signage using the labels – for example, a Notice sign above pull stations while a building fire system is being repaired,” says Geary. “A custom sign like that could cost about $40 each. For one time temporary projects, it would be much better to simply print it on demand at a lower cost.” The removable signage is also helpful in lab settings, particularly those that change frequently. According to Geary, the OSHA Laboratory Safety Standard requires safety notifications, including emergency contacts and potential hazards at the entry to a lab as part of the Hazard Communication to ensure anyone entering is informed of the risks and wears necessary personal protective equipment (PPE). “The removable signs are great for posting in areas with high lab turnover, or short term projects, particularly university or R&D labs,” says Geary. “Because the people and the chemical hazards change frequently in such settings, using a permanent sign is not practical.” Administrators, facility managers, and safety officers will also want signs compliant with OSHA 1910.145 (Specifications for Accident Prevention Signs and Tags) and ANSI Z535.4 (Product Safety Signs and Labels). Although standardized safety signs can be purchased out of catalogues, there is often a need to modify or customize mandated signage as conditions or formats change. On-demand printing solutions, however, have traditionally required a large upfront investment of thousands of dollars, including a specialized sign and label printer, software, labels, and ribbons. In response, industry innovators such as Avery have developed a simplified, flexible approach using standard laser

Miniaturized Wireless Medical Wearables Miniaturized Wireless Medical Wearables Tiny RF chip antennas are no longer relegated to PCB “keep out” area, allowing product designers to further miniaturize wireless biosensors and medical wearables Traditionally, small chip antennas used in RF-enabled medical devices have required a designated ground “keep out” area to minimize interference from other components and ensure the ideal radiation pattern for wireless signals. In some cases, this reserved space can eat up as much as 15 x 20mm of the printed circuit board. However, with the drive to further miniaturize next generation medical biosensors and wearables, new alternatives are entering the market that allow the chip antenna to be mounted directly above metal surfaces. By doing so, as much as 10-20% of the space traditionally reserved for the keep out area is no longer required, allowing designers to reduce the overall size of the product. This has major implications for wireless medical devices in which even miniaturized PCBs along with coin-cell batteries often utilized are limiting factors in the minimum form factor. Products that could be positively affected by this development include an array of “smart” devices such as watches, clothing, eye glasses, patches, pills and even adhesive bandages. Mobile Health Biosensors and Wearables For the medical industry, the “future is now” when it comes to miniature battery powered sensor devices that can be located near, attached to, or implanted in the body to monitor physiological signs such as temperature, blood pressure and pulse rate. These smart devices will soon monitor everything from fitness to health, environment, lifestyle and behavior. Biological parameters than can be tracked include vital signs, sleep, emotions, stress, breathing, movement, efforts, posture, gait, body shape, lesions, mental acuity, toxins, blood glucose, ECGs, and drug adherence. The information collected is then wirelessly transmitted to nearby cell phones, remote monitoring stations or through Wi-Fi over the Internet to back-end servers for further analysis, assessment and decision making. Collecting data in this manner is expected to facilitate the development of disease models and an understanding of the complex behavior of biological networks. Mobile health data can also be a valuable tool for drug discovery and clinical research. Among the products already incorporating this type of technology are adhesive bandages that contain built-in sensors that measure heart rhythm, respiratory rate and temperature. These readings can be used, for example, to determine the precise amount of insulin that should be dispensed from wirelessly controlled insulin pumps worn by diabetics. Top of Form Embedded Chip Antennas To transmit and receive RF wireless signals in the appropriate frequency range, smart devices must contain small RF chip antennas embedded on the PCB or behind the scenes underneath the encasement of the product. These chip antennas radiate and receive electromagnetic waves as other types of antennas, but the most notable difference is its small size. In fact, today’s mobile phones incorporate a minimum of four antennas and up to 13 in some models. Smaller wearable devices may only contain one or two antennas. To work properly, chip antennas have typically been ground plane dependent, meaning they require an appropriately sized and positioned ground plane to form a complete, resonant circuit. While the PCB can serve as the ground plane, the antenna itself must typically be placed on the edge of the board in an isolated section which is free from ground and metal components that would distort its radiation. Without the isolation distance, the performance of the antenna is significantly affected. “The ‘keep out area’ is fundamental to ensure the chip antenna can electromagnetically radiate to antenna applications, because everything affects the radiation pattern including the package size, where the antenna is mounted and its proximity to the human body,” says Manuel Carmona of Johanson Technology, a leader in high frequency ceramic components including chip antennas, High Q capacitors and EMI chip filters. According to Carmona, Johanson Technology has been able to eliminate the requirement for a designated ground keep out area through optimization of materials (ceramics and inks), manufacturing processes and RF circuit design. The new 2.4 GHz antenna can now be mounted directly onto the metal ground plane. The product measures 2 x 5mm and is designed for small coin-cell battery operated IoT, 2.4 BLE, wearable, ISM, ZigBee, and 802.11-standard applications where metal or a battery/display covers the entire length or side of the PCB. “With PCB real estate at a prime, the size and placement of the chip antenna is critical because as everything gets smaller it becomes increasingly difficult to place more components on the board,” explains Carmona. “Therefore, design engineers are looking to component manufacturers to deliver miniaturized solutions that occupy next to no real board space.” The design of the antenna itself is also critical to its range and performance. With medical devices, radio interference or some other glitch could result in interrupted connectivity. There can be legal ramifications as well. As with any wireless device, products that utilize RF technology, including Bluetooth, to collect or transmit information are subject to regulation by the Federal Communications Commission (FCC). Therefore it is critical the device perform at the designated frequency and the design and placement of the antenna is critical to proper tuning. Despite the critical nature of the antenna, Carmona says it is often overlooked until late in the design process, at which point optimal antenna performance may not be achievable within the space provided. To assist with chip antenna design and selection, Johanson Technology offers a program where design engineers can send in a miniaturized device and the company will tune the antenna for optimum functionality. “A chip antenna that can be mounted over a ground plane opens up many applications for products that want to incorporate wireless,” says Carmona. “To date, we have received everything from smart shirt buttons to jewelry and other wearables in various shapes and sizes.” For more information, contact Johanson Technology at (805) 389-1166, e-mail antenna@johansontechnology.com or visit www.johansontechnology.com/ant. The company is located at 4001 Calle Tecate, Camarillo, CA 93012.

Scanning Acoustic Microscopy: Taking it from the Lab to High Throughput Fab Scanning Acoustic Microscopy: Taking it from the Lab to High Throughput Fab The demand for equipment that can perform non-destructive imaging and materials analysis has increased significantly for silicone ingots, wafers, integrated circuits (ICs), MEMS and other electronic packages produced by the billions in automated production environments. Today, however, the continuously evolving high volume production requirements are rapidly migrating beyond the products that were recently considered standardized in the industry. New device designs, packaging methods, shrinking dimensions, bonded wafer interfaces and demand for increase product yields are driving market demands for significantly improved capabilities and sophistication of production equipment. These challenges also include higher levels of automation integration for component handling, improved clean room performance requirements as well as scanning of ever smaller components and interface connections. For these reasons Scanning Acoustic Microscopy (SAM) technology continues to advance and is now rapidly becoming the technique of choice. SAM utilizes ultrasound waves to non-destructively examine internal structures, interfaces and surfaces of opaque substrates. The resulting acoustic signatures can be constructed into a 3 dimensional images which are analyzed to detect and characterize device flaws such as cracks, delamination, inclusions and voids in bonding interfaces, as well as to evaluate soldering and other interface connections. “Using ultrasound provides a clear advantage in ensuring good adhesion and mechanical integrity of devices,” says Peter Hoffrogge, Product Manager of PVA TePla Analytical Systems GmbH, a company that designs and manufactures advanced Scanning Acoustic Microscopes. Compared to alternative techniques like X-ray that are used to evaluate volumes and densities, ultrasound looks at interfaces, says Hoffrogge. “In the example of a sinter connection on a power device, the gaps are only a few nanometers,” says Hoffrogge. “With X-ray you don’t get any contrast, so you can’t tell whether the die has adhesion through the interlay or not. With ultrasound, it is easy to see.” The challenge today is to perform this inspection at extremely high throughput with 100% inspection to identify and remove components that do not meet quality requirements. Often, these defects can occur in different layers of the device. This necessitates more advanced equipment that simultaneously inspect several layers, often on multiple channels scanning multiple samples in handling trays in automated fashion to accelerate the process. However, as with other inspection systems, increasing throughput requirements traditionally has required sacrificing image resolution. Fortunately, Hoffrogge says today’s advanced inspection equipment can overcome these limitations. Much of today’s equipment is custom designed to be completely, integrated into other high volume manufacturing systems. This includes models specifically designed for inspection of items such as crystal ingots, wafers and electronics packages in a range of standard sizes. For items with more unique product geometries or sizes, Hoffrogge says equipment can be semi-customized to meet the requirement of the application based on established, common components. Acoustic Scanning The unique characteristic of acoustic microscopy is its ability to image the interaction of acoustic waves with the elastic properties of a specimen. In this way the microscope is used to image the interior of an opaque material. Scanning acoustic microscopy works by directing focused sound from a transducer at a small point on a target object. The sound hitting the object is either scattered, absorbed, reflected (scattered at 180°) or transmitted (scattered at 0°). By detecting the direction of scattered pulses as well as the “time of flight,” the presence of a boundary or object can be determined as well as its distance. To produce an image, samples are scanned point by point and line by line. Scanning modes range from single layer views to tray scans and cross-sections. Multi-layer scans can include up to 50 independent layers. Pre-Developed, Integrated Systems Today, SAM equipment exist that have been pre-developed to handle standardized items such as bonded wafer inspection of MEMS, CMOS imaging sensors, etc. These equipment test for inclusions or delaminated areas in the bonding interfaces and other defects. “Typically damage inspection is performed in late stage of production to make sure the device is error free, 100% flawless. It is typically done before dicing,” says Hoffrogge. According to Hoffrogge, PVA TePla’s bonded wafer inspection tool, AUTO WAFER, is optimized for high throughput with 4 transducers and automated wafer handling. Cassette loading systems facilitate quick loading (open load port, SMIF, FOUP or customized input and output cassettes), robots for handling 5-12 inch wafers, integrated scanners for wafer tracking, along with other features required of such systems. For volume inspection of single crystal ingots (e.g. Si, Ge, GaAs) a multiple transducer scanning system (4 heads) is used to estimate the 3-dimensional location of defects inside the crystal volume. In this way, the tool is capable of analyzing voids and inclusions, estimating their depth and size simultaneously. The tool can inspect 5-12 inch Si ingots up to 400 mm thickness and a weight of 75 kg. The defect resolution may reach down to 100 μm voids in Silicon. Hoffrogge says there are a significant number of systems in production performing inline inspection of sensitive electronic devices transported in JEDEC-Trays. Regardless of the type of component inspected, each system includes integrated data analysis and automation software, GEM/SECS interface for fab host communication and other key features. Customized Equipment For applications with unique product geometries and sizes, companies like PVA TePla can build on core platform components that utilize the latest technology. When even higher throughput is required, up to 4 transducers can simultaneously scan for higher throughput. Multiple transducers can be used on a single substrate and the images then stitched together, or multiple transducers can simultaneously scan multiple substrates. Throughput can also be increased by incorporating ultra-fast single or dual gantry scanning systems or 6-axis robots. Other possible add-ons include rotation axes (flipping), vacuum chucks and customized water tanks. “We have a large portfolio of core components which have become standard for us that are used or modified to provide rapid solutions to our customers,” says Hoffrogge. “We basically have the complete value chain available

BBB’s Torch Award for Ethics: Arizona Foundation Solutions Selected as Finalist for Second Year in a Row BBB’s Torch Award for Ethics: Arizona Foundation Solutions Selected as Finalist for Second Year in a Row The Better Business Bureau (BBB) serving Central, Northern and Western Arizona has selected Arizona Foundation Solutions as a finalist for the 2018 Torch Award for Ethics, the most prestigious honor the BBB can present to a business. This is the second consecutive year the company has been selected as a finalist. Encouraging and supporting ethical business practices is a key purpose of the BBB. Being a recipient of the Torch Award indicates that a business not only believes in the high standards promoted by the BBB, but also consistently acts on them and continuously integrates them into daily practices. While Arizona Foundation Solutions, a Phoenix-based foundation repair specialist, was a finalist as a category III company (21-50 employees) last year, it returns as a category IV company (51-150 employees) this year, indicating significant growth. “We are honored to again be a finalist of the BBB’s Torch Award for Ethics, and believe in treating homeowners fairly, accurately, objectively, using consensus industry standards,” says the company’s founder, Bob Brown, one of two Certified Foundation Repair Specialists (CFRS) in the state. With more than 30 years of industry experience, Brown has been a long-time advocate for Arizona homeowners dealing with foundation problems. His e-book, “Which Way is My Foundation Moving?” is described as a homeowner’s guide to foundation repair and is available for free download from the company’s web site. Brown is also calling for a change in the way the foundation repair industry “sells” homeowners. The common foundation industry practice is to send salespeople with no engineering education, trained only by a single source product supplier, to diagnose the foundation problem, recommend a solution and close the sale in a single visit. Instead, he is calling for the entire industry to abandon that sales model in favor of one in which experts, in this case trained engineers, diagnosis foundation repair issues. While this may seem obvious, this is a fundamental change in the way the industry has operated for decades. Brown also continues to innovate, and has even developed specialized products and techniques to address unique Arizona soil conditions like heave, an uneven foundation lift resulting from moisture expanding clay soils found over most of the state. To learn more about foundation problems, causes and potential solutions, visit Bob Brown’s Blog: Leveling with Bob (http://www.foundationaz.com/) or call (623) 748-4859.

Comprehensive Emergency Lighting System Solutions from Single Source Providers Comprehensive Emergency Lighting System Solutions from Single Source Providers From lights to exit signs, a single source emergency lighting system product supplier can streamline the design process for electrical engineers For electrical engineers responsible for designing a building’s emergency lighting system, the process of selecting and integrating the various component parts from lights to exit signs is not a one-size-fits-all proposition. After all, there are a myriad of combinations and approaches available that will sufficiently provide one foot candle of illumination along the path of egress specified by the NFPA. These options often begin with deciding on the type of power source that will be used in the event of a power outage. Often, existing architectural lights are incorporated if possible, powered by centralized inverters or generators. However, when that is not sufficient, dedicated battery powered emergency lights may be required. In an industry flooded with inexpensive, commoditized products, another key decision is whether to specify higher end, architectural alternatives. Dedicated emergency lights, for example, can be concealed until needed behind panels that can be covered by wallpaper or matching wall paint, if desired. Even emergency exit signs require consideration, with options ranging from inexpensive thermoplastic models to more elegant, energy efficient models. Additional challenges can occur within the design and specification process as well. Although electrical engineers are well trained in emergency lighting system design, it is often one of the last aspects considered. This can create difficulties sourcing and receiving items – often from multiple parties. However, for those emergency lighting product companies that provide a full catalogue of options from lights to exit signs and inverters, much of the pain can be taken out of the process by simplifying the interaction and providing a single source. “Electrical engineers prefer not to source items from three different companies: one for the exit sign, one for the inverter, and another for the lighting,” says Bill Lynch, President of Isolite Corporation, a company that offers high quality, specification grade emergency lighting products. Design-Conscious Emergency Lights Dedicated emergency lighting is often utilitarian, obtrusive and unsightly. One of the most common, low cost options involves two lamps and a bulky battery pack that is often referred to as a “bug-eye” light. Fortunately, more stylish options exist. At the top of the list is incorporating existing architectural lighting into the emergency lighting plan. In this approach, the architectural lights operate as normal. If utility power is lost, however, supplemental power can be supplied via an inverter or generator. While this approach is ideal, there are many situations in which the existing lighting will not provide the requisite illumination along the entire path. When this occurs, lighting designers often seek out more high-end, stylish fixtures. Even items such as bug-eyes and exit signs are available in more aesthetic versions. When emergency lighting is necessary, one of the most aesthetic options is actually to conceal it until it is required. Some ingenious units are even designed to blend in with the existing decor by being painted or covered with wallpaper. For example, one manufacturer of specification-grade emergency lighting products, Isolite, offers the Genie, along with a more compact version called the Mini Genie, that remain fully recessed behind two flat panel doors until required. “If power is lost, the battery-powered units automatically open to light the way,” explains Lynch. Exit Signs Although exit signs must be functional, they do not need to be ugly. A variety of aesthetic options exist including slim profiles, specialty finishes, and recessed power supplies that help units blend in with interior decor and architectural features. Because exit signs operate 24/7, however, they should also be energy efficient. As such, some energy efficient LED edge-lit exit signs use less than 3 watts and offer a 3-hour emergency run time with a battery diagnostic monitoring system. Today, new “dual technology” exit signs are even combining the efficiency of LED lighting with revolutionary new photoluminescent materials to increase reliability and performance over decades of use. This hybrid approach combines two established exit sign technologies in a single unit – LED and photoluminescence. During normal power conditions, the sign is illuminated with highly efficient LEDs. When the power goes out, a translucent exit stencil diffusor made of photoluminescent material provides the illumination. This is charged by the LEDs while electric power is provided to the sign. “Although LED technology has improved to the point where it can last over 20 years, battery technology has not kept pace and has been the weak point in exit sign reliability and maintenance,” says Lynch. “Hybrid LED/photoluminescent technology eliminates this weakness and provides more reliable operation for decades.” Inverters When a building-wide power outage occurs, electrical engineers have several options when it comes to powering emergency lighting systems mandated by the NFPA and International Building Code (IBC). The first is to install dedicated lighting fixtures that provide temporary power from built-in battery packs. The other is to utilize centrally located inverters tied to back-up batteries that can provide utility-grade power to both existing architectural and dedicated emergency lighting in the event of a power outage. For engineers that must select an inverter, calculating the size needed as well as AC load requirements is a relatively simple matter. However, there are multiple factors that should also be considered in making a final inverter selection that best suits the application. These include selecting inverters that provide pure sine wave AC power, operate at their designated rating, and provide automated testing/reporting. Given the increasing use of LEDs in architectural lighting, it is important to select an inverter that incorporates pure sine wave technology. Pure sine wave inverters provide cleaner, utility grade power than modified sine wave models and work better with LED drivers. In addition, pure sine wave models have a high surge capacity which means they are able to exceed their rated wattage for a limited time to meet the high inrush currents of LEDs. “When utility power is lost and

Savvy Interior Designers Turn to the Internet to Save Up to 25% on Custom Lampshades Savvy Interior Designers Turn to the Internet to Save Up to 25% on Custom Lampshades Buying online direct from a quality domestic resource can enhance aesthetics, speed delivery, and eliminate retail middlemen When interior designers and decorators craft beautiful, cohesive designs in homes and commercial properties, a crucial element of such projects is how custom lampshades compliment both lamps and the overall look. “As beautiful as a lamp can be, if it does not have the right shade, it is like a person wearing a bad hat,” says Melissa Warner Rothblum, co-owner and principal designer of Massucco Warner Miller (MWM), a West Coast-based interior design firm that does mostly residential projects nationwide. “Getting the right lampshade that fits properly and matches the furnishings is important to the overall design of any room.” Whether for homes, offices, or high end retail establishments, customizing lampshades in size, shape, color, or fabric to enhance aesthetics, or replace a damaged shade, is essential. However, buying shades with enough design flexibility, from retailers with limited inventory, can be challenging. “When buying a retail off-the-shelf shade, you are often limited to small, medium, or large in one or two colors,” says Warner Rothblum. “Customizing locally may not be an option, or can be costly or slow. Professionals need a more sophisticated, custom range of design options.” Now instead of ordering from traditional retailers, a growing number of astute interior designers and decorators are opting for a better choice: purchasing custom shades direct from a quality domestic resource online while saving up to 25%. This is dramatically extending the design palette while cutting out the middleman and speeding delivery. Custom On Demand MWM blends color and textural palettes that range from bold, stunning, and edgy, to soft, tranquil, and serene, while seeking to be clear, fresh, and on point. As such, the firm implements a wide range of vintage lamps and other finds, custom gilded hand-embroidered wallpaper, as well as timeless well-made furniture in all shapes and sizes. According to Warner Rothblum, because of all the design factors involved, custom shades are often necessary to improve the aesthetics of any room with a lamp. While she has also worked with local retailers to make custom lampshades for various projects, it was also relatively slow and costly. As an alternative, she turned to Jack of All Shades, an Alabama based resource for custom hardback lampshades for 30 years that specializes in online sales to the interior design and decorator industry. The company offers a wide range of hardback lampshade options, which run the gamut in shape (round, square, oval, rectangle, drums, pendant, and half round or square); in size (from small chandelier type to 72” oversized); and in color (with a palette of over 130). It also offers a number of fabrics (linen, silk, burlap, weave, poly cotton, faux leather, leather laced or washable/easy to clean) as well as lampshade fitter types. “What we like about the custom shades is that we can specify all the details and get exactly what we want,” says Warner Rothblum. “We can specify the fabric, the height, the top and bottom measurement, even details like trim and edges, so the lamp and room look their best.” According to Warner Rothblum, MWM typically buys 12-15 lampshades per project, about 99% of which are custom. She says that customizing the shades provides both geographic and seasonal flexibility. “Certain parts of the country are more formal and may want a silk shade, and other parts are more casual so would prefer linen,” she says. “Seasonally, if we are doing a summer home in Santa Barbara, we may want lighter colored linen; if doing a winter home on the East Coast, we may want a shade with a heavier fabric.” Warner Rothblum appreciates how Jack of All Shades allows MWM’s interior designers to use their own fabrics and materials in custom shades whenever design coordination is important. “Sometimes we want to use a specific fabric pattern on a shade or a very specific color, so being able to use our own material is really helpful,” says Warner Rothblum. On a recent whole home remodel, for example, Warner Rothblum says that the ability to use MWM’s own fabric, a caramel-ivory patterned linen; with an English barrel shade helped the dining room feel cohesive. “If we had done a simple white silk shade, the lamp would have felt more formal,” says Warner Rothblum. “Because we did a fun pattern on the shade, it made the lamp feel more edgy and chic. It is actually one of the client’s favorite things in the whole house. They loved the shades in the dining room.” Because design details can seem less important, but also make a difference, MWM’s interior designers also specify shades with a rolled edge when the occasion calls for it. A special handmade “rolled edge” eliminates the need for trim. Instead of traditional 1/2” trim, the fabric forms the finished edge of the shades for a clean look that is becoming a trend in venues aiming for a modern vibe. Compared to purchasing custom lampshades at retail prices, where available from local shops, Warner Rothblum says that buying online direct from the source also offers significant savings. “We have saved up to 25% over retail buying direct from Jack of All Shades,” says Warner Rothblum. She says that ordering online is actually easy. “We typically select all the options we want from the website,” says Warner Rothblum. “If there are any additional details we need to specify, we talk with them directly.” When Modern Drama, a Chicago, IL based supplier of rare and iconic furnishings for mid-century interiors, required custom lampshades to accompany restored lamps, owner Ryan Bennett tired of waiting for local shops to finish the work. “Previously, I bought custom shades from local retailers, but it took up to six weeks for them to be delivered and the price was

Damage Free Sign Labels for Schools and Universities Damage Free Sign Labels for Schools and Universities Customizable sign labels, printed with laser or ink jet printers in minutes, can be removed cleanly from most surfaces, reducing repair and repainting, while serving myriad functions in every area of campus Throughout K-12 schools and college campuses, signs are used virtually everywhere. Signs are posted on surfaces from the front gate to the front office, from attendance to counseling, from teachers’ rooms, conference rooms, break rooms, and resident halls to gyms, libraries, auditoriums, and student centers. Signs are used in many ways, whether informal, formal, or mandated by law. In offices or classrooms, signs establish rules or procedures, request sign in, as well as inform or teach. In hallways and common areas, signs notify or remind. Across campus, signs provide directional guidance, identify events or locations, call out points of interest, or specify areas as dangerous or off limit, which is vital when construction, remodeling, or refurbishing is occurring. Often permanent signs are not an option because the information changes and needs to be updated. In these situations, options for administrators and facility managers are limited. Because signs can be located in high traffic areas, the sheets of paper, cardstock, sheet protectors, laminated sheets, and posters used must not only present a professional image, but also stand up to the environment. This is where the problem lies. Since many signs are not designed for high traffic use, they may not look professional or be resistant to wear and tear from frequent touching, handling, or the cleansers used in such environments. As a result, they are damaged easily and must be replaced frequently. Many signs can also cause considerable damage to the underlying surfaces when taped, tacked, nailed or screwed to walls, glass, or equipment, which can hasten the need for costly repair and repainting. Sign removal can also leave behind unsightly residual tape or adhesive. This is exacerbated when signs include information that is routinely changed or updated, such as for seasonal operating hours or instructions. With premature campus repair and wall repainting costing schools and universities many thousands of dollars in annual maintenance, the ideal solution would be signage that is easy to install, durable enough to endure harsh conditions, yet comes off easily when necessary, leaving no trace. This can significantly reduce the need for campus maintenance, freeing up resources for higher priority educational purposes. “Commercial-grade labels used as signage must be more durable than those used in a lower use area, but also should remove cleanly when they need to come down,” says Tina Huff, Group Product Manager at Avery Products Corporation. “For us, the key to accomplishing this was developing an adhesive that holds well but can be removed when needed. Achieving that balance is harder than it sounds.” As a result, Avery created Surface Safe Sign Labels – an exclusive, proprietary product specially engineered to stick securely yet remove cleanly without damage or residue from painted walls, doors, windows, furnishings, equipment, and other interior surfaces. These “labels used as signs” are made of durable, commercial-grade material that resists water, chemicals and even abrasion. Available in a variety of sizes, they print easily on standard laser or inkjet printers, opening a world of possibilities for custom, do-it-yourself signs. Unlike standard office labels with a paper substrate, the topcoat of the commercial-grade sign labels is waterproof and chemical resistant, while its polyester substrate is a durable, scuff and tear-resistant film. These qualities are ideal for safety-related signage mandated by regulation or required by educational policy. For instance, administrators, facility managers, and safety officers will want signs compliant with OSHA 1910.145 (Specifications for Accident Prevention Signs and Tags) and ANSI Z535.4 (Product Safety Signs and Labels). Although standardized safety signs can be purchased out of catalogues, there is often a need to modify or customize mandated signage as conditions or formats change. On-demand printing solutions have traditionally required a large upfront investment of thousands of dollars, including a specialized sign and label printer, software, labels, and ribbons. In response, industry innovators such as Avery have developed a simplified, flexible approach using standard laser and ink jet printers. The company’s free online Design and Print Software enables customizable printing utilizing OSHA/ANSI compliant templates. Educators and support staff can create and print their own informal, formal, or compliant labels from pre-designed templates or create them step-by-step on demand at a desk or service counter. Most find the process intuitive, since it resembles creating an office document from pre-designed templates. With the variety of signage used throughout school and college campuses, the ability to conveniently print new sign labels in minutes and cleanly remove the old will go a long way toward keeping the whole educational community safely up to date and professional looking without the hassle, mess or cost. For more information visit www.Avery.com/signs.

Extending the Life and Improving the Performance of Plastic Injection Molds Extending the Life and Improving the Performance of Plastic Injection Molds Coating mold components like ejector guide elements, cores, lifts and cavities increases the lifespan of molds while reducing maintenance and running costs It is well known that the molds used to create plastic parts ranging from water bottles to automobile bumpers are the most critical – and expensive – part of the injection molding process. In some cases a single mold can cost hundreds of thousands of dollars, not including the ongoing maintenance and running costs. However, despite being made of hardened steel, the very process of injecting melted resins at high temperatures and pressure into cavities over many cycles begins to wear away and erode the surface of cavities and moving components. Even the thermoplastic material itself can be abrasive or “sticky,” acting like sandpaper or leaving residue that wears down the surface. Now, with the increased utilization of even more abrasive material in the form of long glass and composite fibers, the amount of abrasion and friction within molds is increasing. Subsequently, molds are taking even more of a beating. It is for this reason that injection molders are turning to a variety of coatings to protect their investment and reduce maintenance and running costs. These coatings, applied to mold cavities as well as moving, sliding components within the mold, come in a variety of styles from carbon-based coatings, PVD & PACVD deposition to nitriding techniques that share one overriding goal: hardening the surface of the steel to protect it against all manner of abuse. “These coatings are applied for the simple fact that steel alone is not hard enough to protect these expensive molds and ensure optimal uptime and productivity,” explains Thomas Vermland, Global Application Manager for Oerlikon Balzers, a company that has been producing specialized PVD coatings for components and tools for more than 30 years. Reinforced glass fiber products In the automotive industry, manufacturers are placing greater emphasis on design and weight reduction. Subsequently, automotive designers are increasingly using glass fibers as reinforcements in many parts, including automobile bumpers. As a result, automobile bumpers are constructed using less material than before. “Inside the mold there is more pressure and higher temperatures being used to inject the plastic by a factor 2-4 times higher than in the past,” explains Vermland. This inevitably creates more friction (sheering effect) which can cause polymers like polyethylene or a polypropylene to become unstable during crystallization. To compensate, reinforced glass fibers are often utilized as an economical way to create a lighter, stronger part that retains some flexibility. Initially, when short glass fibers were used this did not create much of a problem because it did not affect the crystallization significantly. The slightly abrasive nature of the glass fibers also had a positive “cleaning” effect by removing residue on internal cavities caused by outgassing. However, the long glass fibers popular today are more abrasive, resulting in micro cutting within the mold’s cavities and runners due to sharp, jagged edges and a hardness of up to1200 HV. This can create significant issues, particularly along the parting line and any sharp contours within large molds. For large molds like those used for automobile bumpers and tailgates, a nitriding process can be used to significantly increase the surface hardness of the metal. Nitriding is a heat treating process that involves hydrogen, plasma and electricity that creates a case-hardened diffusion layer on the surface of a metal. Because it is not a coating, it does not affect the overall dimensions of the component. Vermland says Oerlikon Balzers’ BALINIT PRIMEFORM diffusion treatment increases injection mold surface hardness up to 1400 HV. This makes the molds significantly more robust (including versus long glass fibers) and reduces residue build-up, spalling and edge embrittlement. “We can take the entire bumper mold and place it in the machine and treat it in one operation,” says Vermland. “With the diffusion treatment process we can take a base steel and harden the first hundred microns of the surface to Rockwell hardness well above 65. The rest of the steel remains unaffected.” This is the replacement for Hard Chrome in any big mold. Vermland adds that a large steel mold of 65 HRC could not even be manufactured due to its size. With the surface now harder than that of the glass fibers and any additives, repairs and re-polishing are reduced as much as 80%, according to some customer experiences. “Now the OEM or Tier manufacturers can run many more shots before they have to stop the machine for cleaning or to perform repairs because the surface is much harder. It also prevents residue build-up caused by out-gassing,” adds Vermland. The BALITHERM PRIMEFORM diffusion treatment is also ideal for automotive plastic parts with mirror-polished surfaces, such as those used to produce bumpers headlights, tail lamps, and brake lights or large interior parts with high quality demand like piano black. The mirror-polished surfaces of plastic injection molds are very sensitive and so require more surface cleaning, and protection. Failing to do so can allow dust and other particles into the mold that influence the quality of the end product. With its superior polishing properties, BALITHERM PRIMEFORM improves surface brilliance and eliminates the need for mirror re-polishing after cleaning. In this way, heavily stressed areas are rendered wear resistant and are protected against scratching, environmental factors and improper handling. PVD Coatings for Cavities, Moving Parts For injection mold cavities, fixed items such as guide pillars and sleeves or for moving and sliding components within the mold, carbon-based, physical vapor deposition (PVD) coatings can be applied to prevent galling and wear. “When you apply carbon-based coating to these types of components, you can extend service life, enable longer runs between repairs and increase performance,” says Vermland. Carbon-based coatings such as BALINIT C, BALINIT TRITON or BALINIT DYLYN from Oerlikon Balzers, are thin (approximately 2 – 3 microns) and provide extremely hard layers to the surface of components and cavities. The most critical

New Dry Erase Capability Helps Office Product Manufacturers Think Outside the Box New Dry Erase Capability Helps Office Product Manufacturers Think Outside the Box Unique coil coated product can be formed and integrated into new office product shapes, while providing better performance than traditional options While dry erase boards have long been a staple in just about every boardroom, classroom, and meeting room, manufacturers typically have been forced to choose from expensive, heavy glass or porcelain construction or cheap melamine products that, to a large degree, had to be manufactured into rectangular boards or panels and inserted into frames. Furthermore, the less costly options tend to ghost (erase incompletely), often require thorough cleaning with liquid cleaners, and wear more easily, leading to premature replacement. Now advanced coatings applied to steel coil substrate are enabling office product manufacturers to think outside the box by allowing cutting, bending and forming of a dry erase surface not only as doors, wall panels, and cubicle partitions, but also as curved surfaces and even 3D shapes. In addition to cutting down the weight, the dry erase coating also reduces ghosting, and even allows for sublimation printing of logos and branding. This could include photo quality images or other graphics for industry or customer specific purposes. Post Formable Dry Erase Coatings While traditional dry erase materials are readily used in standard whiteboard shapes and sizes, they are not compatible with more complex forms. As such, they tend to corral office product manufacturers into rectangular “inside the box” thinking. “Porcelain and glass covered dry erase surfaces cannot be formed, which limits their potential use in a wider array of office products,” says Dan Chin, President of Universal Chemicals & Coatings (Unichem), a custom adhesives and coating formulator, “Their weight also poses limits in the size, application, and mounting of the dry erase boards.” A new approach of a specially formulated coating to aluminum and steel coil substrate is promising to dramatically expand the possibilities of how a dry erase surface can be used and incorporated into office products. Coil coating, a high speed efficient coating process, involves the use of aluminum, cold rolled steel or hot dipped galvanized steel which can be efficiently coated, re-coiled, and then shipped for later fabrication and forming into parts or products. Unlike porcelain and glass, a coil coated substrate with a special dry erase coating can be precision slit, stamped, sheared, roll formed, and incorporated into virtually any size or shape that coated coiled metal can be configured. Manufacturers like Unichem, for instance, have developed coatings for coil substrate that can be post formed to accommodate a manufacturer that wants to form whiteboards into wall panels, partitions, or office furniture installations. In fact, their coatings are used on the dry erase panels at one of the world’s leading office furniture manufacturers. Because of how flexibly the coated coil substrate can be formed, it is also suitable for entirely new applications, including aesthetically curved or 3D surfaces, which manufacturers, architects and interior designers may dream up. Additionally, dry erase installations utilizing the specialty coating weigh only a fraction of comparable porcelain applications, and similar glass applications. This can simplify any wall or partition mounted installation, as well as make furniture lighter and more easily moved and shipped. Better Erasability, Less Ghosting In addition to the increased design options, manufacturers are also solving the omnipresent issue of ghosting and shadowing at a substantially lower cost than either glass or porcelain. Some coil coated substrates, in fact, have been tested with over a hundred markers from a wide array of manufacturers, even some permanent marker manufacturers. With over 10,000 cycles of erasability, heat and humidity cycling, and cleanability, the finish exceeds the industry’s stringent requirements, so even permanent markers clean off with spray cleaners. As a matter of fact, a Fortune 20 technology company recently chose to apply one such coating, called Uni-rase, on all the white boards at its new world headquarters. “In the erasability tests, the coating has to show little to no wear through all the mark-erase cycles,” says Chin. “It’s also important to build in resistance to moisture because some common dry erase products tend to ghost severely in high humidity climates.” Photo Quality Graphics A dry erase board by definition is designed so ink will not stick. As such, typical dry erase materials usually provide only a simple graphics capability by printing. However, the availability today of photographic quality sublimation inks, along with specialized coatings, makes the printing more impactful, complex images that enhance the brand possible. “Now you can infuse (sublimate) permanent inks into the coating – such as for photos, logos, patterns, calendars, or industry specific formats or graphics – yet retain dry erase board erasability,” says Chin. “The image in the coating is every bit as good as the actual printed photo, so it enhances visual impact and aesthetics.” The sublimation process used to achieve this essentially introduces heat to turn solid ink particles directly into a gas which permanently colors the surface and sub-surface of the dry erase board, so the ink will not wash away, according to Chin. Though the dry erase market has changed relatively little in decades, the recent introduction of unique coatings is now changing the industry and providing office product manufacturers with creative new ways to better serve their customers. For more information, contact Unichem at: 1975 Fox Lane, Elgin, IL 60123; or Call: +1 (847) 931-1700, Fax: +1 (847) 931-1799; email: sales@unicheminc.com or visit online at www.unicheminc.com

Custom Formulators Create a Better Bond with Laminated Coil Custom Formulators Create a Better Bond with Laminated Coil OEMs turn to custom formulators to solve complex adhesion problems with laminated coil and sheet metals For manufacturers that utilize flat-rolled steel, aluminum and other metals to fabricate parts or products, the ability to bond decorative foils and laminate films to the substrate provides an opportunity to deliver attractive finishes for a competitive edge. Decorative finishes include the look of stainless steel, brushed copper, and wood grains, as well as a variety of colors, imprints, and gloss grades. Laminate films can also serve a functional purpose by providing scratch or chemical resistance. However, the process of laminating to metals is fraught with potential complications. If the wrong adhesive is utilized, if the curing process is not precisely controlled or a variety of other variables are not managed, the result can be a high scrap rate or parts that fail in the field. When this occurs, OEMs and even the coil processors that supply them with bare or B-stage (pre-applied adhesive) coil turn to custom formulators for unique solutions to production issues. In many cases, the proper adhesive formulation can have significant benefits such as speeding production, eliminating scrap, reducing the amount of material required and even improving corrosion, UV and antimicrobial resistance. Options for applying laminate The use of laminate applied to metal to fabricate parts or products is widespread throughout manufacturing. Some of the more common applications including appliances (refrigerators and freezers, washing machines, dishwashers, microwaves, range or fume hoods), construction products (insulated wall panels, garage doors, roofing products) and the mobile and manufactured home markets (walls, door panels). The processing of adhering laminates to coils of metal or sheets occurs in several different ways. Manufacturers can employ in-house personnel to spray or brush adhesives within the plant. However, this process is slow, requires manual labor and brings up safety and environmental concerns. Quality can also be an issue and scrap rates are frequently quite high. Automated equipment can also be used to apply foils and films to flat-rolled metals that come with pre-applied B-stage adhesive from a coil processor. This type of adhesive is designed to activate and cure within a specific temperature range. The laminate is then applied to the coil at the manufacturer’s plant using furnaces and nip rollers. Although automated processing is much faster and more efficient, it can also lead to quality control issues due to temperature variances within the curing ovens involved. In some cases, scrap rates can be as high as 20%. “Application of adhesives in the final manufacturing facility can lead to significant amounts of scrap, higher per piece labor costs, and can expose the manufacturer to significant environmental costs and scrutiny,” says Eric Fossen, managing director of Spencer Ridge Consulting of Ontario, Canada. “So they often are looking for a more efficient solution that gives them a more consistent [laminate] performance.” Fossen, who serves as a consultant to the coil processing industry, says the simplest solution for OEMs is often to outsource the process completely. This eliminates the need for in-house labor, application equipment, curing ovens, and environmental control facilities. Adhesives applied in a coil coating operation offer the advantage of a high degree of consistency in both film thickness and cure conditions, which can provide a stronger and more durable adhesive bond. High quality application allows the final product to be post-lamination formed into many severe bends and shapes without affecting the integrity of the bond between adhesive and film. Adhesive Quality Although coil processors control the application process much more tightly, the quality of the bond ultimately depends on the type of adhesive used. According to Fossen, many adhesive manufacturers offer a variety of off-the-shelf options, but will not customize a product to meet a customer’s unique requirements unless very large volumes are involved. “With large adhesive suppliers, if they have a product that works – great. If not, they are often not willing to tweak the product to make it work for a specific application,” says Fossen. When this occurs, coil processors and even OEMs turn to custom adhesive formulators with the expertise and experience in coil processing to come up with unique solutions to solve difficult problems. Case in point – Door Panels For Elixir Door Company, manufacturing entrance doors for manufactured homes involved vinyl-coated steel that was stamped and formed before being filled with urethane foam for insulation and structural strength. To accomplish this, Elixir Door ordered coil-rolled steel with pre-applied B-stage adhesive. The vinyl was then applied using curing ovens and nip rollers at the manufacturing plant. Approximately 2-3 years ago, however, the company began to experience significant adhesion problems leading to a high scrap rate. “The vinyl was coming off in major proportions – not just a ‘spot here’ or a ‘spot there,’ but in many places. It was very inconsistent,” explains general manager Archie Brown. Unable to identify the reason, Brown says he called in a custom adhesives and coating formulator, Universal Chemicals & Coatings (Unichem). The company specializes in coil processing and can create custom adhesives and also coatings. The solution involved an adjustment to the temperature parameters of the curing oven as well as a custom-formulated adhesive from Unichem designed to cure within a broader temperature range. “Unichem analyzed our entire process and came up with some corrective actions,” says Brown. “We adjusted everything and have had no problems since.” According to Brown, Elixir Door subsequently decided to outsource the entire process. Now the coil processor delivers a finished, vinyl-coated part using Unichem’s adhesive formulation that is already sized and stamped into shape. “We were paying [the coil processor] to apply adhesive, then paying to apply the vinyl in house. Now they do it all in one operation at their facility,” says Brown. “So our cost is much less and we don’t have to worry about scrap because it’s on them, not us anymore.” Case in Point – Roofing plates Unichem has also

Improving the Life and Performance of Critical Aerospace Components Improving the Life and Performance of Critical Aerospace Components The aerospace industry is increasingly turning to PVD and PACVD coatings to increase the durability, performance and service life of components – and as an alternative to hard chrome Aerospace OEMs and MROs are continually seeking new ways to improve the performance and longevity of critical aerospace components such as those used in turbines, flight control systems, landing gear and hydraulic systems. To achieve this, these components must be designed and manufactured to withstand erosion, corrosion, extreme temperatures, high loads and even metal-on-metal contact. However, there are additional challenges to consider beyond extending component life. Namely, the more immediate goal of finding new ways to increase the operational performance and fuel efficiency of aircraft through refinements in component and system design, materials and coatings. Even seemingly minor factors such as the surface finish of compressor blades, for example, play a key role in increasing the fuel economy of high bypass ratio turbofan engines. Today, this is putting renewed attention on coating, plating or nitriding options that modify the surface of critical components to improve wear and corrosion resistance while providing for example the required coefficient of friction for metal-on-metal contact or the erosion resistance necessary to maintain surface finish requirements for optimum airflow in gas turbines and therefore engine efficiency. This comes at an opportune time, given the industry’s transition away from hard chromium plating to more environmentally friendly alternatives. For many years, hard chrome plating was the standard for achieving wear and corrosion protection, but due to the European REACH regulations the application of hard chrome plating is now highly regulated. Now these challenges are increasingly being met by thin film coatings applied by PVD and PACVD as well as with other techniques such as nitriding, which can provide even greater durability than hard chrome plating while still providing similar functional properties. Aerospace-Specific PVD Coatings Approved and field-tested in the aerospace industry, physical vapor deposition (PVD) and plasma-assisted chemical vapor deposition (PACVD) can be used to deposit thin film coatings to harden the surface of components. This can significantly increase the lifespan of components, reducing maintenance and downtime. The coatings also have the advantage of being thin, typically 1-5 µm in thickness but can be up to 25µm for specific erosion restiant properties. Coating tolerances can be as low as +/-0.5 µm over a surface. This feature, in conjunction with close tolerancing, means that the component retains its form, fit and dimensions after coating without the need for re-machining. One PVD coating, called BALINIT Turbine Pro from Oerlikon Balzers, is specifically geared towards protecting engine compressor blades, vanes or integrated bladed rotors (blisks) from erosion, pollution and corrosion. Often, previously these blades are left unprotected. Oerlikon Balzers, a long time coating provider working in the aviation industry for over 20 years, recently achieved NADCAP accreditation at its facility in Guelph, Canada, which serves the US and Canadian aerospace markets. The company also operates NADCAP accredited customer centers in France, the UK and Luxembourg. “In the aircraft industry, the goal is to reduce fuel use as much as possible,” explains Oerlikon Balzers Global Aerospace Segment Manager Toby Middlemiss. “To do this, manufacturers often polish the compressor blades and blisks to mirror finishes. This increases the airflow through the engine, which ultimately increases fuel efficiency.” However, Middlemiss says that as blades foul in service, the efficiency of the compression system eventually drops. “The debris particles in the air erodes the surface finish of the blades, they begin to get a matte finish and ultimately lose performance,” says Middlemiss. “By applying the [BALINIT Turbine Pro] coating, you can maintain the highly polished surface finish and retain the efficiency gain.” BALINIT Turbine Pro utilizes a metal aluminum nitride (MeAIN) structure that results in an optimal relation of high hardness to residual compressive stress even under high thermal conditions. It can be applied to steels, super alloys and titanium components and has an extremely low surface roughness (down to 0.05Raµm) once the process is applied. The high hardness of BALINIT Turbine Pro has already been proven in solid particle, liquid droplet, liquid cavitation, waterjet and other erosion tests with the coating on various substrates (steel, Inconel and titanium) in different coating thickness and high temperatures. In the solid particle erosion test in which materials were evaluated based on mass loss, for example, BALINIT Turbine Pro demonstrated more than four times higher erosion protection than other PVD coatings, including titanium nitride (TiN). That value increased to more than 40X when compared to uncoated titanium and even more for steel. Alternative to Chrome Plating PVD and PACVD coatings also provide a viable alternative in replacing hard chrome plating. Hard chrome plating has been consistently used in the aerospace industry to protect components from fretting, corrosion and wear. However, due to the carcinogenic hexavalent chromium salts used in the hard chrome plating process, the US OSHA and the EU REACH have imposed tight restrictions on chromium and cadmium plating. Therefore, existing parts made with chromium and cadmium plating will need to be replaced and new parts will need to be manufactured using environmentally safe materials. According to Middlemiss, some OEMs have attempted to replace hard chrome plated steel with uncoated, hardened stainless steel. The problem with this method is that stainless steel has poor low-frictional wear and sliding properties. Another option that has been adopted is the use of tungsten carbide based thermal sprays. However, these coatings often require quite a bit of post-coating processing and time consuming grinding, which drive up the costs. On thin walled parts the relatively thick thermal spray coatings can also result in unwanted stresses and distortions of the components. A better option is BALINIT C, a WC/C ductile carbide carbon of the DLC family (a-C:H:Me) coating that provides excellent wear and scuffing resistance while simultaneously reducing wear and friction for bearings, shafts and pins using in landing gear and engine mounts. The BALINIT C coating has a high load-bearing capacity even under conditions of deficient lubrication or dry contact. Due to its low friction coefficient, it reduces pitting

Simplifying Moisture Measurement to Optimize Pulp and Paper Quality and Production Efficiency Simplifying Moisture Measurement to Optimize Pulp and Paper Quality and Production Efficiency Instantaneous, “point-and-measure” handheld analyzers that can be operated by virtually any technician deliver lab-quality moisture readings in seconds In the pulp and paper industry, measuring and controlling moisture content can impact product quality, production throughput, and processing efficiency, as well as the purchase price of wood chips, pulp, and converted paper products, not to mention shipping costs. As paper is made from pulp wood fibers that are boiled, bleached, strained, flattened, dried into continuous webs, and then converted into various paper products, measuring and controlling moisture content is critical every step of the way. Whether producing air dry pulp, roll pulp or converting to newsprint, magazines, books, boxes, bags, labels or packaging materials, measuring precise moisture levels is essential. A pulp or paper product’s quality, drying efficiency, as well as transactions based on weight, can be adversely affected by improper moisture content. Furthermore, the satisfaction of strict international specifications can be a determining factor influencing a mill or converter to measure moisture content. However, until recently conducting frequent moisture content tests throughout the process or in the field has been difficult. In many cases, the primary barrier has been the expertise and time required to conduct such tests. Often, sophisticated moisture measurement devices must be operated by trained personnel that can properly calibrate the equipment. Many also require meticulous sample preparation and disposal. Fortunately, handheld devices are now available that allow even less-skilled personnel to take lab-quality moisture measurements. These “point-and-measure” options allow moisture readings to be quickly taken at any stage of the process, as well as at loading docks, on trucks, at suppliers, or in bins, vats or vessels. By simplifying the process, pulp and paper producers and converters can increase the quality of their products from wood chip receipt and pulping to end product conversion and distribution. The Many Benefits of Moisture Readings Although the reasons for measuring the moisture content of pulp and paper products can vary, the primary motivation is to improve quality and the bottom line. As such, monitoring and controlling moisture content in all stages of production ensures the most efficient processing and resource use, while increasing the customer’s satisfaction with the product. In pulp milling, if there is too much water in wood chips, it can affect physical and chemical processing into wood pulp. If too much water is in paper pulp during a process, the paper can fall apart so measuring and achieving the correct moisture content is critical. In terms of quality control, there are strict international specifications required for pulp by the paper industry. Failing to meet required standards can result in rejected product or even fines by customers and clients. Air dry pulp, for instance, which is usually delivered as sheeted bales, leaves about 10% moisture in the pulp to minimize fiber to fiber bonding, while easing pulp dispersal in water for processing into paper. Roll pulp is typically dried to 5-6% moisture content for easier processing. To optimize quality and processing, it is also important to analyze continuous paper webs for wet streaks and uneven drying. Since all of a paper product’s physical properties such as curl, porosity, permeability, opacity, smoothness, roughness, stiffness, breaking strength, compression strength, and tear resistance also depend on measuring and controlling moisture content, this is crucial. Other conversion processes such as calendering and printing also depend on working with the materials at specified levels of moisture. While drying has been reported to account for 12-20% of industrial energy consumption, drying processes can be particularly energy-intensive operations in the pulp and paper processing industries. As such, measuring moisture content in batch or continuous drying processes can help to optimize the process and significantly reduce energy costs. Finally, since moisture content contributes significantly to the weight of pulp and paper, properly drying a product to acceptable limits before it is transported can significantly reduce shipping costs. Simplifying Moisture Measurement Although traditional laboratory and online based moisture measurement techniques are useful in the right settings, they have lacked the simplicity and flexibility required for frequent spot checks. One common test is Loss on Drying, which measures the total material weight change after drying. However, such tests typically require a sample to be prepared and brought back to the lab. The test takes at least 15 minutes to several hours to perform, which is too slow when more immediate measurements are required. It also requires the sample to be altered or destroyed. The other common test is a Karl Fischer (KF) test. This procedure calls for chemical reagents to be added to the sample to separate the water from the remaining product and is normally used on liquid samples. The water removed is then compared with the initial mass or volume. Samples are generally small, making the assumption that a large batch is homogenous. Also, since the chemical reagents need to be used, skilled personnel are required to determine the initial parameters, confirm that the system is properly calibrated and maintained and, at times, required to actually conduct the tests. Disposal of the reagents and waste can be subject to substantial documentation and costly handling. As a result, secondary test methods have typically been used to deliver faster results. This type of test uses an indirect method and a single conversion to achieve accurate results. Secondary measurement techniques are routinely accepted as equal to the gold standard method. Examples are speedometers, common infrared and liquid thermometers and most pressure gauges. If there is a disadvantage, it is that the instrument must first be calibrated to ensure accurate results. In some cases, calibration could only be performed by trained staff familiar with the equipment. In response, industry innovators have developed a simplified approach that allows even less-trained personnel to take portable, instant moisture reading spot checks of pulp and paper industry inputs, in-process conditions, or finished products as needed. This can be

Withstanding Extreme Wear in Ag Handling Equipment Withstanding Extreme Wear in Ag Handling Equipment Urethane provides greater wear resistance than steel or rubber, at lighter weight, and can be customized to meet individual specifications Agricultural bulk handling equipment such as chutes, spouts, elbows and distributors can experience severe wear when transferring millions of bushels of ag products annually, particularly at transitions or rough areas, where “hot spots” of abrasion can occur. In such cases, the bare structure of the equipment may not be adequately wear resistant and even traditional steel or rubber protective liners may insufficiently control the abrasion. This can pose a risk of costly spillage and production downtime for clean up and repair. For such applications, sheets made from urethane (short for polyurethane) provide far better wear resistance than more traditional options such as steel or rubber. Urethanes are cost-effective, dependable elastomers that combine some of the performance advantages of high-tech metals, ceramics, and plastics, along with the flexibility and resiliency of rubber. Because of this, thinner cross sections can be applied at lighter weight, allowing easier installation. Now this “tougher than steel” liner can actually be cut from full sheets of various sizes to fit the contours and shapes of high contact areas, so it can easily be glued, bolted, or welded to provide extreme wear protection wherever it is required. While such liners are commonly cut to fit and installed onsite, custom liners made to fit important transitions or more complex configurations can increase reliability, simplify installation, and further reduce production downtime. Extreme Wear Resistance The outstanding abrasion resistance of urethane elastomers has led to many important applications where severe wear is a problem in industries as varied as agriculture and mining. “Rubber is not as abrasion resistant as urethane, and fancy steel liners do not provide sufficient resistance either,” says Charles Pratt, Operations Manager at Kinder Australia, an independent supplier and manufacturer of conveyor and bulk material handling equipment. Pratt turned to a proprietary urethane formulation called Kryptane, an extremely wear-resistant material for applications where abrasion, sliding, or impact occurs regularly, by Argonics, one of the U.S.’s largest producers of wear resistant urethane products. The liner is FDA Drygood Handling approved. Examples of its use include chute, bin and hopper liners; pipe, fitting and valve liners; and conveyor liners that withstand abrasive materials. “In testing for some applications, we found that the urethane skirtings on the outside of a conveyor can last 10-15 times longer than rubber,” says Pratt. “Compared to a steel liner on the inside of a conveyor, a urethane liner can get 5-8 times the life.” Because of its extreme wear properties, the urethane liner excels in grain handling applications. The urethane liner is also resistant to cracking, tearing, breaking, as well as sunlight and temperature cycling, which furthers its reliability in such settings. “I have used Argonics lining material at our grain export terminal for over 10 years,” said Bill Hoffer, a retired chief millwright of CHS Inc., a farmer-owned cooperative working to help America’s farmers be more successful. “I have not had to replace any of these liners installed over the last 10 years. We export about 43 million bushels of grain through the system each year and the Kryptane liners show little sign of wear.” In many such grain, seed, or rice bulk handling applications, self-installation of the liners is common, according to Doug Maves, an Argonics product engineer. “When agricultural users only need minor trimming or simple cutting to line a straight chute or standard shape, they often measure and cut the sheets themselves onsite,” says Maves. Standard sheet sizes are 4’x8’, 4’x10’, 5’x8’ and 5’x10’, in thicknesses from 3/16” to 1”; rolls are also available – 4’x25’ up to 5’x100’. The material can be installed/fastened using a bolted technique, glued or welded in place to create rugged and durable lining for chutes, spouts, and other agricultural bulk handling equipment. Polyurethane coated bolts are also available when using a bolt-in technique. Maves notes that plain liners are suitable for lighter duty applications. For heavier duty applications, he suggests using a backing to prevent potential stretching and to help improve the integrity of the fastening method. “When gluing a liner to a structural surface, fabric backed sheets can achieve a stronger adhesive bond,” says Maves. “When bolting a liner, expanded metal or solid metal backed sheets can provide extra strength and rigidity.” Custom liners are also available for more complex transition points. These can be engineered and manufactured to the finished size/geometry required by the manufacturer to easily drop into place. This minimizes production downtime along with eliminating the need for measuring, cutting and/or trimming the standard sheet product in order to fit the application. “If the liner requires a tighter fit, a complex shape, or multiple pieces to fit certain transition points, then working with the manufacturer for a custom fit may be a better option,” says Maves. He notes that such custom fittings increase liner reliability as well as reduce waste, installation time, and production downtime, since fewer sheets, fewer cuts, and less adjustment is needed for onsite installation. The process for customizing liners is quite simple for agricultural end users. According to Maves, the end user typically provides a sketch, drawing, or photo of the bulk handling equipment to be lined, along with dimensions and notes. The manufacturer then finishes the drawings and provides a quote; if the end user approves, the liner is completed, shipped, and is ready for installation when received. Whether used as standard or custom liners, urethane’s extreme wear resistance can offer agricultural design engineers, equipment manufacturers, or end users years or even decades of trouble free handling of bulk products. For more information contact Argonics, Inc., 520 9th St., Gwinn, MI 49841; visit www.argonics.com; call 800-991-2746; email information@argonics.com.

Contractors Profit by Expanding into Functional Fabric Wall Systems Contractors Profit by Expanding into Functional Fabric Wall Systems New alternative opens a host of lucrative markets, while free training and assistance helps contractors get productive fast Contractors are discovering a new profit center by installing versatile, stretched fabric wall finishing systems instead of going with the usual options of paint, traditional upholstery, or wrapped panels. The benefit of a stretched fabric wall surface is that it transforms a wall into a beautiful, functional surface. It is tackable like a bulletin board; has acoustical properties that reduce noise and sound transmission through walls; and can withstand high impact in high wear areas so is very low maintenance. The system is also versatile since refreshing the walls or updating the colors requires only changing out the fabric. Such fabric wall finishing systems are easily installed on site. A variety of fabric types, colors and patterns are available. Even floor-to-ceiling, high definition graphics can be printed on the fabric. Various multi-panel designs can be installed from railroad track designs to abstract, curved, and custom shaped patterns using flexible track. With so many options, site fabricated wall coverings can be used to conform to most architectural features. Best of all, there are no up-front costs for contractors – and free training, support, and assistance is available to help them thrive when adding such offerings to their existing services. “When I first installed a stretched fabric wall finishing system in my studio, I never dreamed it would lead to doing contract work in so many homes, offices, schools, restaurants, companies, and movie studios,” says John Cox, President of John Cox Integrations (JCI), a Southern California based contractor of residential/commercial remodeling and new construction. “We have even done work on Steve Carell’s home theater, and Snoop Dogg’s production studio,” adds Cox. “The system has created a profitable business for us because there are so many opportunities for installing it.” A Versatile New Approach In Cox’s case, the fabric wall finishing system he utilizes is manufactured by Fabricmate, a Ventura, CA based producer of innovative wall finishing systems. To accommodate the diverse needs of contractors, the wall finishing supplier offers its products in a wide range of sizes from ready-to-hang premade panels and ready-to-install modular panel kits to site-fabricated wall finishing systems. The covering can be installed on top of any existing surface, so it can be used to quickly refresh a site’s look, or for complete remodels and new installations. Each panel consists of three parts: a fabric covering, a backing material, and a fabric mounting frame. The fabric covering is stretched over the backing and held taut by the fabric mounting frame. This allows the panel surface to spring back when struck, effectively mitigating visible damage allowing for years of performance. The excess fabric is rolled into the frame for a clean look. The frame and backing can be reused, and the fabric changed out as desired. The backing fills in the frame and covers the wall, providing a pinnable bulletin-board like surface for tacking things up, along with impact resistance and the ability to absorb reverberated sound waves that would otherwise bounce off the walls. The fabric mounting frame holds the fabric in place. For contractors concerned about ease of installation and productivity, installing the wall finishing system can actually be faster than painting when preparation and clean up is taken into account. “We can install a typical site fabricated Fabricmate wall finishing system faster than a drywall company can tape it, texture it, and paint it, including drying time,” says Chad Cossey, treasurer and lead foreman at Santa Maria Acoustical Co. Inc., a Grover Beach, CA based acoustical contractor specializing in suspended ceilings, acoustical/tackable wall panel systems, and wall protection systems. The system can also install over unfinished drywall, so there is no need to mud, texture or prime; just tape the drywall joints. Additionally, the system can adjust to match out-of-true conditions so it can be installed on walls, ceilings, soffits and alcoves with no unsightly gaps. “With traditional wrapped panel systems, we previously had to make the panels fit every spot,” says Cossey. “Now with the stretched fabric wall system, we can wrap columns, go around windows, and essentially do everything. The one system handles it all.” Help With Projects and Profitability There is ample help available at no cost to contractors of any experience level looking to add the fabric wall finishing systems to their professional repertoire. Cossey, for instance, appreciates the hands–on training and instruction that some manufacturers provide at the outset to get contractors started, teach installation shortcuts, and other tricks of the trade. He acknowledges that online webinars are available today, as is access to best layout practices and instruction sheets. He notes, however, that early and ongoing manufacturer support can really make a difference in how quickly a contractor can learn the trade and become profitable. “On our first project, Fabricmate sent a crew of people to work alongside us at our jobsite for a couple of days,” says Cossey. “This helped us quickly get up to speed, work through any questions, and successfully complete the job. Years later, I still consult with them once in awhile to get ideas and advice. I may ask ‘How do you think this would work?’ on more complex projects.” Other job support is provided to contractors as well, such as online access to various project resources. These can range from a material calculator to a submittal and substitution builder, which can help contractors quickly gather all the data sheets, testing documents, and certifications needed to create a complete submittal or substitution. Some manufacturers will also work directly with contractors in the concept and planning stages of a project. This can assist in the design, functional requirement analysis, layout, material selection, and setting of installation schedules to help contractors meet client requirements as cost effectively as possible. JCI’s Cox relates how good manufacturer support can help contractors profitably expand their opportunities along with their skillset. “Installation

Preventing Costly “Lights Out” Fines and Downtime Preventing Costly “Lights Out” Fines and Downtime Smart trailer lighting systems maximize fleet uptime while minimizing maintenance costs and CSA exposure For OEMs, fleet managers and owner-operators of Class 7 or 8 trucks, keeping all the various lights on a trailer functioning properly can eliminate a considerable amount of trouble. This includes avoiding CSA fines or citations for severity points, but also eliminating a glaring reason for law enforcement to pull the vehicle over. In fact, more than 25% of all CSA violations in the heavy-duty trucking industry are related to lighting outages from inoperable lamps or defective/broken lights. As such, it represents one of the largest annual expense items, when CSA fines, maintenance, downtime and repair are factored together. Given that lighting-related CSA violations are so common, the industry is responding with new “smart” systems that provide continuous, real-time monitoring of all lights on the trailer to identify outages or electrical shorts. For notifications and alerts, today’s solutions go far beyond the flashing indicator lights of the past. In more advanced systems, real-time status of every light on the trailer can be transmitted via on-board telematics or wirelessly through Bluetooth where it can be accessed through a user-friendly smartphone app. Armed with this level of information, owner-operators as well as fleet and maintenance managers are able to maximize safety and increase uptime, while minimizing CSA exposure. Lighting Systems Get Smarter Every trailer requires fully functioning lamps at all times on the road. This includes those for stop, left and right turn signal, tail, license, clearance, side marker, and identification. However, problems arise due to lamps burning out, corrosion in the wiring or plugs, electrical shorts or issues related to shock, vibration, or physical damage. Fortunately, lighting issues are typically resolved quite easily with spare fuses, replacement lights/bulbs and the right tools. The difficulty, therefore, is simply knowing a problem exists so it can be addressed immediately. Although pre- and post-trip inspections (if conducted diligently) may expose a problem with one or more of the lights, outages that occur while on the road may not be known about until much later. As already suggested, this could draw the attention of law enforcement and even up the possibility of additional CSA citations. “Lights that are out are an easy target for a state trooper,” says Kevin Cornelius, Business Development Manager of Power Delivery at Grote Industries, a global manufacturer of lighting and safety equipment for trucking fleets. “When a truck is pulled over, it can trigger the officer to investigate everything else like the driver logs, brake wear or tire tread.” Although there are lighting monitoring products available, until recently there have been a few drawbacks, says Cornelius. One system utilizes only a flashing light to indicate an outage. Another uses an indicator light on the outside of the truck, but can also be connected to telematics. However, it works only with LEDs and requires extensive trailer alteration for installation. However, a new approach called the Grote Guardian Smart System can be easily integrated into the trailer’s wiring harness system at the nose box. The system was created in collaboration with one of the largest trailer manufacturers in North America, and is currently being used by more than a dozen fleets across the country. The fully integrated smart system delivers real-time status of the entire trailer lighting system and works with any type of lamp. The system’s sensor continuously monitors voltage and current passing through the wire harness. The system is programmed to differentiate notable or sudden changes from those that are gradual and could be caused by lights warming up or ambient temperature conditions. The system alerts a driver, maintenance or fleet manager using a smartphone app or it can be connected to the on-board telematics system. All the information on status and any changes are logged in cloud-based storage for data analysis. According to Cornelius, the same sensors could be used to measure temperature, humidity, pressure, or other factors as part of a bumper-to-bumper solution as the industry moves more toward monitoring of additional tractor-trailer functions. Because of the importance of collecting accurate data, Cornelius adds that the wire harnesses used should be extremely reliable and resistant to corrosion for the smart systems to function optimally. For this reason, he recommends utilizing wire harnesses that are resistant to moisture, chemical and UV attack, which will stay flexible and not harden or crack. Although this type of wire harness is available from Grote, Cornelius notes that the Grote Guardian Smart System works with wire harnesses and lamps from other manufacturers as well. Next Generation Smart Systems One aspect of the next generation system from Grote, planned for release in April, 2018, that is of particular interest to trailer OEMs and fleet managers is a “geo-fence” feature that will automatically upload trailer lighting and electrical system information and send alerts for priority attention, as needed. Geo-fencing allows a virtual geographic boundary to be drawn around a specific location, such as a facility or repair depot. When the geo-fence is crossed and there is a lamp or light outage, it can be programmed to automatically trigger a warning via e-mail or text message to appropriate personnel. “Once the tractor-trailer crosses the established geo-fence, the maintenance manager will immediately be notified,” explains Cornelius. “This approach could even allow for automatic electronic ordering of replacement lamps, if desired.” Although some companies charge a monthly subscription fee for this type of service, Cornelius says Grote has no current plans to charge for the geo-fencing feature. “The ability to proactively identify and resolve any lighting, electrical, or other tractor-trailer issues will only grow as this kind of real-time monitoring system becomes more sophisticated,” concludes Cornelius. “In the trucking industry, access to this type of information is going to reduce CSA violations and ensure safer, simpler operation.” For more information, contact Grote at 2600 Lanier Drive, Madison, Indiana 47250; phone: +1 (800) 628-0809; e-mail: info@grote.com; or online at www.grote.com/guardian.

Simplifying Moisture Measurement to Improve Food Quality Simplifying Moisture Measurement to Improve Food Quality Instantaneous, “point-and-measure” handheld analyzers that can be operated by virtually any technician deliver lab-quality moisture readings in seconds In the food processing industry, controlling the moisture content in dry good ingredients can impact product quality, formulation, processing, shelf life and even shipping costs. Therefore, accurate measurement of moisture content is essential throughout the process and even with the final product. Until recently, however, conducting frequent moisture content tests in the field has been difficult. In many cases, the primary barrier has been the expertise and time required to conduct such tests. Often sophisticated moisture measurement devices must be operated by trained personnel that can properly calibrate the equipment. Many also require meticulous sample preparation. Fortunately, handheld devices are now available that allow even less-skilled personnel to take lab-quality moisture measurements. These “point-and-measure” options allow readings to be quickly taken at any stage of the process including at the supplier, in receiving areas, in-process (prior and post-mixing) and on the finished product. By doing so, food processers can ensure a more consistent, high quality product ultimately reaches the consumer. The Benefits of Frequent Moisture Readings Although the reasons for measuring the moisture content of dry good food ingredients can vary, the primary motivation is to improve product quality and the bottom line. In terms of quality, incorrect moisture content in dry ingredients can lead to soggy products as well as alter its taste, texture, and appearance. Shelf life is also directly affected by moisture content. If there is too much moisture, mold can develop or the product can spoil in the package. Too little moisture and the product can become stale much faster. Establishing the moisture level of dry ingredients that must be mixed together is also very important, as it can affect how the ingredients blend together, dissolve, or flow through the process. Finally, since food products are sold by weight, packaging and shipping the product at optimum moisture percentages can also help optimize the purchase price and freight cost. Simplifying Moisture Measurement Although traditional laboratory and online based moisture measurement techniques are useful in the right settings, they have lacked the simplicity and flexibility required for frequent spot checks. One common test is Loss on Drying, which measures the total material weight change after drying. However, such tests typically require a sample to be prepared and brought back to the lab. The test takes at least 15 minutes to several hours to perform, which is too slow when more immediate measurements are required. It also requires the sample to be altered or destroyed. As a result, secondary test methods have typically been used to deliver faster results. This type of test uses an indirect method and a single conversion to achieve accurate results. Secondary measurement techniques are routinely accepted as equal to the gold standard method. Examples are speedometers, common infrared and liquid thermometers and most pressure gauges. If there is a disadvantage, it is that the secondary instrument must first be calibrated to ensure accurate results. In some cases, calibration could only be performed by trained staff familiar with the equipment. In response, industry innovators have developed a simplified approach that allows even less-trained personnel to take portable, instant moisture readings of dry good food ingredients as needed. The approach involves moisture meters that utilize Near-Infrared (NIR) light, a highly accurate, non-contact secondary measurement method that can deliver immediate laboratory quality moisture readings. “NIR moisture meters allow very accurate instant measurement of solids, pastes, and liquids without contact or sample preparation, so there is no contamination in handheld and online models,” says John Bogart, Managing Director of Kett US, a manufacturer of a full range of moisture and organic composition analyzers. “Once the meter has been calibrated against the lab or production standard, the calibration is stored in the device so no calibration is required in the field. Measurements are fully traceable to the original measurement method.” In addition, because the process is non-destructive, samples remain unaltered so they can be used for additional tests or put back into the product stream. “NIR moisture meters follow the principle that water absorbs certain wavelengths of light,” says Bogart. “The meter reflects light off the sample, measures how much light has been absorbed, and the result is automatically converted into a moisture content reading.” Unlike complex laboratory equipment, portable NIR equipment is designed for ease of use. For example, with Kett’s KJT130 Handheld Portable Instant Moisture Meter, the user simply points the instrument at the food ingredient and the moisture content is instantly shown on a digital display, with results accurate to .01% in a 0-100% measurement range. Because no direct contact or sample alteration is required, unusual textures and particle size variation are not an issue. This can be important when used with a range of food ingredients in different settings. For ease of use, the unit is operated via user friendly menu commands. The unit, which is the size of a camcorder, is designed for frequent spot checks wherever necessary, on both stationary and moving (process line) products. Moisture measurement data may be stored in the instrument, downloaded continuously, or manually recorded. “The goal is for any staff member to be able to successfully use the moisture meter wherever it is needed, with minimal required training,” says Bogart. “This allows food processors to have the certainty that what they are producing is of the highest quality. “The key is to cost-effectively be able to conduct as much testing as required, with full confidence in the results, each and every time,” adds Bogart. For more info, contact Kett: call 800-438-5388; email support@kett.com; or visit www.kett.com.

Damage Free Sign Labels for Industrial Use Damage Free Sign Labels for Industrial Use Sign labels that can be printed with laser or ink jet printers in minutes and removed cleanly from most surfaces serve to notify, instruct, and even protect personnel in just about every area in a facility Throughout industrial plants and warehouses, signs are posted virtually everywhere from the production floor and inside the warehouse to staff offices, conference rooms and even the break room. In most facilities, there is virtually no room or area spared from these notifications, instructions or warnings, whether informal or mandated by law. Signs everywhere Signs are used in multiple ways throughout industrial facilities. In lean manufacturing, signs are often used to establish operating instructions, procedures, processes, checklists and scheduling. In HR, signs give notice, rules, and reminders to personnel. In offices, signs are used to identify locations, prohibit smoking, and request visitor sign in. In break rooms, signs spell out refrigerator rules and remind staff to keep the premises clean. Because many of these signs are located in industrial environments and not in pristine commercial offices, the sheets of paper, cardstock, sheet protectors, laminated sheets, and posters used must stand up to a harsher environment. This is where the problem lies. Since many of the options used for ad hoc signs are not designed specifically for industrial spaces, they are not resistant to the moisture, chemicals, greases, etc. often found in such environments. As a result, they are damaged easily and must be replaced frequently. Many signs can also cause considerable damage to the underlying surfaces when taped, tacked, nailed or screwed to walls, glass, or equipment. Sign removal can also leave behind unsightly residual tape or adhesive. This is exacerbated when signs include information that is regularly updated or changed. The ideal solution would be signage that is easy to install, durable enough to endure harsh conditions, yet comes off easily when necessary, leaving no trace. “Industrial labels used as signage must be more durable than those used in an office, but also should remove cleanly when they need to come down,” says Tina Huff, Group Product Manager at Avery Products Corporation. For us, the key to accomplishing this was developing an adhesive that holds well but can be removed when needed. Achieving that balance is harder than it sounds.” As the result of this effort, new Avery Surface Safe Sign Labels have an exclusive and proprietary construction specially engineered to stick securely yet remove cleanly without damage or residue from painted walls, doors, windows, and other interior surfaces. These “labels used as signs” are made of durable, industrial-grade material that resists water, chemicals and even abrasion. Available in a variety of sizes, they print easily on standard laser or inkjet printers, opening a world of possibilities for custom, do-it-yourself signs. Unlike standard office labels with a paper substrate, the topcoat of the industrial sign labels is waterproof and chemical resistant, while its polyester substrate is a durable, scuff and tear-resistant film. These qualities are ideal for safety-related signage mandated by regulation or required by company policy. For instance, facility managers and safety officers or engineers will want signs compliant with OSHA 1910.145 (Specifications for Accident Prevention Signs and Tags) and ANSI Z535.4 (Product Safety Signs and Labels). Although standardized safety signs can be purchased out of catalogues, there is often a need to modify or customize mandated signage as conditions or formats change. On-demand printing solutions have traditionally required a large upfront investment of thousands of dollars, including a specialized sign and label printer, software, labels, and ribbons. In response, industry innovators such as Avery Products Corporation have developed a simplified, flexible approach using standard laser and ink jet printers. The company’s free online Design and Print Software enables customizable printing utilizing OSHA/ANSI compliant templates. Employees can create and print their own informal, official, or compliant labels from pre-designed templates or create them step-by-step on demand at their desk. Most employees find the process intuitive, since it resembles creating an office document from pre-designed templates. With all the signage used throughout an industrial setting, the ability to conveniently print new sign labels in minutes and cleanly remove the old will go a long way toward keeping the whole facility safely up to date without the hassle, mess or cost. For more information visit www.Avery.com/signs.

Cling’s Aerospace Eliminates the “Weakest Link” in Aerospace Machining Cling’s Aerospace Eliminates the “Weakest Link” in Aerospace Machining Manufacturers are increasing productivity 10-40% and reducing tooling costs by addressing an often overlooked flaw in toolholder-retention knob design High speed machining in excess of 20,000 RPMs is often utilized in aerospace when machining exotic alloys and harder metals like titanium. At these rates of speed, the precise and secure seating of tapered toolholders in the spindle becomes even more critical. So much so, that failing to pay attention to this single detail can lead to decreased productivity, less precise machining, reduced tool life and even damaged workpieces. However, that is precisely what is occurring in aerospace machining due to an often overlooked, even ignored, link in the chain: poorly designed retention knobs that – when tightened – create a bulge in the small end of the taper that prevents full contact and proper seating in the spindle. Yet despite widespread evidence of uneven wear patterns and simple “touch-off” tests that immediately identify it as a widespread issue, the industry has largely ignored this aspect of machining and, unwittingly, are paying a significant price for it. The flaw in the system Although the shank of tapered toolholders is ground to a fine finish within very precise, established tolerances, and are also threaded at the narrow end to accept a retention knob. The knob is designed to engage with the drawbar, which exerts a pull force that holds the toolholder firmly in the spindle. The problem is poorly designed, traditional retention knobs – a less than $30 part – when tightened create a bulge in the taper that prevents proper seating in the spindle. Once this expansion occurs, the toolholder will not pull fully into the spindle and so cannot make contact with upwards of 70% of its surface. The results are manifested in a wide range of CNC milling issues often attributed to other causes: vibration and chatter, poor tolerances, non- repeatability, poor finishes, shortened tool life, excessive spindle wear and tear, run-out, and shallow depths of cuts. “A lot of aerospace work is really tight tolerance,” says Rex Ausbun at Cling’s Aerospace, a company that specializes in complex 4 and 5 axis precision machined parts. “When you see chatter or vibration, you know there is an issue with the toolholder.” According to Ausbun, who is responsible for purchasing all the inserts, tools and other machining accessories for Cling’s Aerospace, “with a tapered toolholder, you want to ‘marry’ it as tight as possible to the spindle to get as much contact across the entire taper as possible. That way, you are not just hitting at the top of the angle.” To accomplish this, retention knobs are used. However, Ausbun says that newer CNC milling machines exert significantly more drawbar pressure on the knobs than in the past. This is compounded by the fact that most retention knob manufacturers provide little information on the proper torque required, a factor that can lead to the improper seating already described above. As a result, Ausbun says several of the retention knobs literally pulled apart during operations. “As drawbar tension continues to increase in CNC machines, it puts so much pressure on the weakest link, the retention knob, that it’s bound to come apart,” says Ausbun. “It’s a significant issue because if the retention knob comes apart while the machine is running it could cause considerable damage,” adds Ausbun. “You are talking spindles that cost $10-$14 thousand a piece today, not to mention the downtime. That’s a lot of money.” High Torque retention knobs To find a solution, Ausbun did some online research and found JM Performance Products, Inc. (JMPP). In 2009, the company introduced its High Torque retention knob. Invented by the company’s founder, John Stoneback, the product works with all existing toolholders including BT, DIN, ISO, and CAT toolholders from 30 taper to 60 taper. The High Torque retention knob is longer by design to reach deeper into the threaded bore of the toolholder. As a result, all thread engagement occurs in a region of the toolholder where there is a thicker cross-section of material to resist deformation. It also includes a precision pilot to increase rigidity, and is balanced by design. Since even over-tightening of the High Torque retention knobs can still create a bulge, the company provides specifically calculated torque specs based on drawbar pressure. By combining the High Torque retention knob with the correct torque, spindle contact with the taper is improved to close to 100% every time. After finding out more information about the product, Ausbun says he decided to order a few and give them a try. In addition to having high hopes for the product, he says he was also impressed that JMPP had researched the appropriate torque settings for installing the retention knobs as well. “When you start checking out different manufacturers as to what they recommend for torque specs on the retention knobs, everyone seems to have a different opinion,” says Ausbun. “I thought it was pretty impressive that [JMPP] went the extra mile and put a lot of research into determining the ideal torque.” Tool life By increasing the rigidity of the toolholder at higher RPMs, the High Torque retention knob can also increase tool life. Perhaps more than some other industries, aerospace manufacturing can take a toll on the carbide cutting tools used when machining exotic alloys and hard metals. The result is that cutting tools must be changed out more frequently as they dull or break. “In aerospace every shop is trying to machine parts faster and aggressively remove more stock, just to stay competitive,” says Ausbun. “This just puts more pressure on the tool.” With higher-end technical carbide inserts, the cost of tool replacement, not to mention loss of production time due to frequent changeover, can add up quickly. “Since we changed to the High Torque Retention Knobs, we are not going through inserts like we used to and we haven’t had

Damage Free Sign Labels for Office Spaces Damage Free Sign Labels for Office Spaces Customizable sign labels, which can be printed with laser or ink jet printers in minutes and removed cleanly from most surfaces, serve a multitude of functions in every corporate area Throughout office settings, signs are posted virtually everywhere from the front door and reception area, to hallways, executive suites, conference rooms, and even the break room. In most instances, there is virtually no room or area spared from these notifications or instructions, including grounds and building maintenance. This is the case whether the signs are informal, formal, or mandated by law. Signs everywhere Signs are used in many ways. In business parks or professional offices, signs can establish regular or seasonal operating hours, provide directional guidance, identify locations, call out points of interest, or specify certain areas as off limits. In office environments, signs are used to identify rooms or conference areas, prohibit smoking, and request visitor sign in. Signs communicate HR notices, rules, and reminders to personnel. In break rooms, signs spell out refrigerator rules and remind staff to keep the premises clean. Because these signs can be located in high traffic areas, the sheets of paper, cardstock, sheet protectors, laminated sheets, and posters used must not only present an impeccably professional image, but also stand up to a harsher environment. This is where the problem lies. Since many of the options used for ad hoc signs are not designed specifically for high traffic office use, they may not look professional or be sufficiently resistant to wear and tear from frequent touching and handling or the cleansers utilized in such environments. As a result, they are damaged easily and must be replaced frequently. Oftentimes, permanent signs are not an option because of landlord regulations. In those situations, options for facility managers can be limited. Many signs can cause considerable damage to the underlying surfaces when taped, tacked, nailed or screwed to walls, glass, or equipment. Sign removal can also leave behind unsightly residual tape or adhesive. This is exacerbated when signs include information that is regularly updated or changed, such as for seasonal operating hours or instructions. The ideal solution would be signage that is easy to install, durable enough to endure harsh conditions, yet comes off easily when necessary, leaving no trace. “Commercial office labels used as signage must be more durable than those used in a lower use office, but also should remove cleanly when they need to come down,” says Tina Huff, Group Product Manager at Avery Products Corporation. For us, the key to accomplishing this was developing an adhesive that holds well but can be removed when needed. Achieving that balance is harder than it sounds.” As the result of this effort, new Avery Surface Safe Sign Labels have an exclusive and proprietary construction specially engineered to stick securely yet remove cleanly without damage or residue from painted walls, doors, windows, furnishings, equipment, and other interior surfaces. These “labels used as signs” are made of durable, commercial-grade material that resists water, chemicals and even abrasion. Available in a variety of sizes, they print easily on standard laser or inkjet printers, opening a world of possibilities for custom, do-it-yourself signs. Unlike standard office labels with a paper substrate, the topcoat of the commercial sign labels is waterproof and chemical resistant, while its polyester substrate is a durable, scuff and tear-resistant film. These qualities are ideal for safety-related signage mandated by regulation or required by company policy. For instance, commercial office managers and safety officers or engineers will want signs compliant with OSHA 1910.145 (Specifications for Accident Prevention Signs and Tags) and ANSI Z535.4 (Product Safety Signs and Labels). Although standardized safety signs can be purchased out of catalogues, there is often a need to modify or customize mandated signage as conditions or formats change. On-demand printing solutions have traditionally required a large upfront investment of thousands of dollars, including a specialized sign and label printer, software, labels, and ribbons. In response, industry innovators such as Avery have developed a simplified, flexible approach using standard laser and ink jet printers. The company’s free online Design and Print Software enables customizable printing utilizing OSHA/ANSI compliant templates. Employees can create and print their own informal, formal, or compliant labels from pre-designed templates or create them step-by-step on demand at a desk or service counter. Most employees find the process intuitive, since it resembles creating an office document from pre-designed templates. With all the signage used throughout commercial office settings, the ability to conveniently print new sign labels in minutes and cleanly remove the old will go a long way toward keeping the whole operation safely up to date and professional looking without the hassle, mess or cost. For more information visit www.Avery.com/signs.

Dealers Turn Detail Departments Into Revenue Sources Dealers Turn Detail Departments Into Revenue Sources Lean production techniques organize equipment, personnel, and materials to enhance sales, productivity, and quality while minimizing waste For too long, the in-house detail departments of new car dealerships have dragged down profit. Yet auto detailing is essential not only to get vehicles into pristine salable condition, but also to earn strong customer satisfaction reviews. One reason for this financial drain has been the industry’s typically disorganized, non standardized approach to detailing, which results in an unnecessarily high cost of labor, chemicals, and materials with slower turnaround and lower quality work. Now, however, top dealers are taking a page from the auto industry’s lean production techniques. They are managing equipment, personnel, and materials to optimize productivity, workflow, and quality while minimizing waste. By doing so, they are transforming their detailing operations from a profit drain into a revenue source. Such an approach can supply superior quality detailing and cut 25% or more of the time and labor needed to ready a vehicle for the lot. It can also save several dollars per vehicle in chemical and material costs for approximately a 1-year ROI. “We have essentially cut our detailing time in half and improved the quality using lean production techniques,” says Chris Davis, Detail Manager at Wagner Auto Group, a full service new and used dealer of BMW, Audi, Mercedes, and Kia vehicles in Shrewsbury, MA. “Superior detailing has become a sales advantage because impeccably clean cars sell and dirty ones do not.” Traditional Inefficiency “While auto detailing thoroughly cleans, restores, and finishes the vehicle’s interior and exterior to show-quality cleanliness and polish, the traditional process costs about $100 including several man hours of labor and about $10 in chemicals and materials before the vehicle is ready for sale on the lot,” says R.L. Abraham, President Emeritus of Detail Plus Car Appearance Systems, a Dallas, Texas-based manufacturer of car detailing equipment. Yet the quality of the detailing is often poor due to a lack of a standardized process, materials and management. Most detailing operations accumulate and store the required equipment, supplies and chemicals in a disorganized manner. Spray bottles, chemicals, buffers, pads, and materials may be in different locations, requiring detailers to leave the service bay to retrieve the items before work can proceed. The detailing steps may be followed, but often not in a systematic order. Furthermore, the process is usually inconsistent, with chemical concentrations varying depending on how much of each chemical is put in the bottle and who is diluting it. Too much time is wasted filling bottles, mixing chemicals, looking for this, waiting for that. Chemical and supply costs also increase due to spills and theft in such operations. Davis says that previously Wagner Auto Group’s detail department spent too much time mixing chemicals, refilling spray bottles, and chasing down materials and equipment. “Downtime does not make dealerships money, so the less time spent locating and setting up detailing equipment and materials the better,” says Davis. When several hundred new and used vehicles may need to be detailed every month per dealership to ready vehicles for sale, inefficient detailing can seriously depress profits. Greater Efficiency Following the lead of the auto industry’s implementation of lean production, popularized by the Toyota Production System, top auto dealers are now learning how to cut the waste from their detailing operations while optimizing workflow, quality, turnaround, and customer value. This is turning previously unprofitable detail operations into revenue sources. “What this approach requires is organizing and controlling the detailing process via centralized stations that anticipate every need and puts it all at the fingertips of the person doing the work,” says Abraham. “This includes the organization of materials at fully supplied workstations with controlled chemical delivery and dilution, along with racks and carts.” One example of this approach that is gaining ground among dealers involves the use of ChemSpense workstations by Detail Plus, which put all the tools and supplies needed by detailers within easy reach so they never have to leave the vehicle or service bay. These are placed on both sides of the vehicle to allow more than one person to work independently at the same time. This increases productivity so more vehicles are detailed per day, and the vehicles get to the lot faster ready for sale. When Wagner Auto Group recently set up a new detailing facility with Detail Plus’s assistance, it included eight ChemSpense workstations along with a variety of other equipment. The workstations dispense up to 12 necessary cleaners, shampoos, and treatments through color coded, chemical lines, eliminating the waste, distraction, and mess associated with squeeze and spray bottles. Even more viscous chemicals, such as waxes, polishes, and compounds, are dispensed through the system, which further expedites the paint finishing process. “Everything is ready right where you need it so there is no wasted time or effort,” says Davis. “With two techs working on a vehicle, we can essentially detail the interior and buff and wax the exterior in approximately 30-45 minutes per car.” Because each workstation includes a powerful wet/dry vacuum, this eliminates the need for clumsy portable shop vacuums. “Our detailers do not have to drag around shop vacuums between vehicles, so there is no worry about bumping them,” says Davis. For cleaning and shampooing carpets and fabric upholstery, each workstation has an internal heated soil extraction system. Two coiled air lines are also available for operating pneumatic tools such as buffers, shampooers, and orbital waxers, as well as to blow dust and dirt out of hard to reach places. “We use one airline to blow dust out of the small cracks and crevices, and the other airline for pneumatic tools like buffers and carpet scrubbers,” says Davis. One key to making the system much more efficient than traditional shops using spray bottles is an accompanying Chemical Dilution and Dispensing System. This chemical distribution center automatically dilutes all water-based chemicals to exact proportions, which improves safety and quality

Pallet Flow Rack Can Be a Warehouse Manager’s Best Friend Pallet Flow Rack Can Be a Warehouse Manager’s Best Friend When properly designed to meet the specific inventory and storage requirements, pallet flow racks maximize storage space and improve shipping logistics Any warehouse or distribution center with limited floor space that needs high density storage or automatic rotation of inventory on a first-in, first-out (FIFO) basis can benefit by implementing pallet flow storage racks. However, achieving the full performance capabilities of this type of rack system requires careful planning and implementation. When this is done properly, pallet flow systems can be the warehouse manager’s best friend; without it, the system may underperform expectations. Simply defined, this type of racking system is designed so that when the pallet in front is removed by a forklift, the pallets behind gently “flow” forward to replace it. Inclined tracks, rollers, and brakes – with an assist from gravity – are used to accomplish this task. New inventory is then loaded at the back end of the rack, facilitating FIFO product rotation, which is particularly valuable for items with expiration dates. In this type of “dynamic” racking approach, goods can be stored 3, 10, even 20 pallets deep and on multiple levels. This eliminates the need for wide aisles between every row of traditional “static” rack required for forklift access and maneuverability. By storing more palletized goods in less space, facility managers can dramatically increase the amount of inventory in a specific warehouse footprint or, on the flip side, reduce the amount of space required for new warehouse construction. “Compared to traditional fixed racking, a high density pallet flow system can essentially cut the required square footage for a warehouse in half,” says Ryan Wachsmuth, Dynamic Storage Sales Manager at Steel King Industries (www.steelking.com), a designer and manufacturer of warehouse material handling, storage and safety products with a national dealer network. “The savings can be significant in terms of reduced property and building costs.” There are substantial logistical benefits to using a dynamic rack system as well. Pallet flow rack can drastically reduce the labor required to pick pallets, because a forklift is only needed for initial loading of the pallets as well as final unloading. With static racks, forklifts must travel further down aisles and often must spend time rearranging inventory to access the correct items. When a large number of pallets with a single product SKU are routinely loaded into trucks, locating the pallet flow rack near the loading dock can also minimize the distance that forklifts travel to as little as 20 feet each way, which speeds material handling. Even pallets with varied SKUs that are being shipped to the same location can be located near each other to further speed truck loading. Designing to Meet Specific Requirements Although the concept of a pallet flow rack may seem straightforward, installing a system that optimally meets a specific warehouse’s requirements takes some planning and collaboration with the vendor. “Many people think you can take pallet flow rack off the shelf and ship it out the door,” says Wachsmuth. “But, it must be designed to accommodate your specific requirements: pallet types, pallet weights, forklift capacity, facility layout and any other restrictions.” According to Wachsmuth, some racking distributors are willing to supply a price quote without fully understanding the requirements of the application. “Not every vendor asks questions to find out what the user needs,” says Wachsmuth. The process ideally begins by understanding the facility’s dimensions, obstructions, types of inventory and forklifts, as well as truck loading and shipping requirements. “It is vital to build the flow rack to take advantage of your warehouse’s full height, width, depth, and floor plan,” says Wachsmuth. “Obstructions like low ceilings or the location of sprinklers, building columns, doors, lights, and vents must be built around.” It is also important to consider the brand, lift height, and weight capacity of the forklifts used at the facility. In general, a forklift’s lift and push/pull capabilities diminish the higher it raises a pallet. “A forklift can cost as much as $100,000,” says Wachsmuth. “So you want to be sure your new pallet flow racks work with the ones you have, or you could have to acquire new forklifts.” In terms of tailoring a pallet flow system to an application, it is necessary to plan for efficient flow storage, loading/unloading, and transport. “Forklift travel distance can be minimized with proper pallet flow planning,” says Wachsmuth. “You don’t have to travel hundreds of feet to pick a pallet. If you install it the pallet flow rack in the ideal location, you may only have to travel twenty feet to pick a pallet. When you return, the next pallet is waiting. This minimizes labor as well as speeds loading and unloading.” Similar planning should be applied to storage depth. Just because the system can be designed 20 pallets deep, doesn’t mean it should be. Instead, it should be designed and grouped to simplify loading/unloading, as well as optimal product rotation. Even some aspects that might seem like smaller details, such as the type of pallet, are important because they affect how pallets “flow” in the system. “There are too many types of pallets with different dimensions today and it could affect the type, and cost, of the pallet flow rack required,” says Wachsmuth. “So, it’s not enough to design on the assumption that a standard 40” or 48” pallet will be used. If the actual pallet has different dimensions, it could increase costs significantly.” With all the aspects that must be considered to get the best results from your flow rack, Wachsmuth adds that it can be helpful to work with a vendor that provides one point of contact for planning, coordination, answering questions, troubleshooting, and resolving any issues. This is far simpler than interacting with a separate pallet flow manufacturer, rack manufacturer, as well as dealer and installer. “Given sufficient planning and coordination, pallet flow rack can be one of the most

Simplifying Moisture Measurement to Optimize Chemical Quality and Production Efficiency Simplifying Moisture Measurement to Optimize Chemical Quality and Production Efficiency Instantaneous, “point-and-measure” handheld analyzers that can be operated by virtually any technician deliver lab-quality moisture readings in seconds In the chemical industry, measuring and controlling moisture content can impact product quality, production throughput, and processing efficiency, as well as the purchase price of feedstock and shipping costs. Whether converting feedstock into products such as synthetic rubber, plastics, polymers, pigments, resins, salts, acids, additives, fertilizers, cleaners, cosmetics, or pharmaceuticals, the amount of moisture in the deliverables can have a wide range of effects. A chemical compound or final product’s quality, drying efficiency, as well as transactions based on weight, can be adversely affected by improper moisture contents. Furthermore, the satisfaction of legal requirements can be a determining factor influencing a company to measure moisture content, which can impact effectiveness. However, until recently conducting frequent moisture content tests throughout the process or in the field has been difficult. In many cases, the primary barrier has been the expertise and time required to conduct such tests. Often, sophisticated moisture measurement devices must be operated by trained personnel that can properly calibrate the equipment. Many also require meticulous sample preparation and disposal. Fortunately, handheld devices are now available that allow even less-skilled personnel to take lab-quality moisture measurements. These “point-and-measure” options allow moisture readings to be quickly taken at any stage of the process, as well as at loading docks, on trucks, at suppliers, or in bins, vats or vessels. By simplifying the process, chemical producers can increase the quality of their products from feedstock receipt, formulation, and processing to end product manufacturing and distribution. The Many Benefits of Moisture Readings Although the reasons for measuring the moisture content of chemical products can vary, the primary motivation is to improve quality and the bottom line. Monitoring and controlling moisture content in all stages of production ensures the most efficient processing, and can increase the customer’s satisfaction with the product. From measurement of incoming feed materials to mid‐process measurement, the optimization of product quality and plant resources will be ensured. Substance interaction can be affected by the presence of moisture. For example, if the moisture content in paint is too high, the adhesion and drying principles of the product will be adversely affected, causing cracking to occur after it dries. If the moisture level is insufficient, premature drying will occur. Establishing the moisture content is also very important when mixing two substances together. If the mixing is not done at the proper moisture levels, the way the two products react can be affected. This includes chemical reactions that take place, the way the two are blended together, or the amount one substance is able to be dissolved into another. It is also important to know the precise moisture content in any feedstock prior to beginning the manufacturing process. Otherwise, its time in the dryer, the dryer temperature, the conveyor belt speed, and many other factors must be modified each time a new shipment is introduced. While drying has been reported to account for 12-20% of industrial energy consumption, drying processes are particularly energy-intensive operations in chemical processing industries. As such, measuring moisture content in batch or continuous drying processes can help to optimize the process and significantly reduce energy costs. Another benefit of frequent moisture measurement is for chemical products sold based on regulated moisture content, which could affect product effectiveness. Prescribed percentages must be met in order to comply with these specifications. In certain industries, heavy fines could be levied, while in others, the product or substance will not be accepted by the regulating agency. These industries can include pharmaceutical, agrochemical, and consumer products, among others. There may even be legal ramifications, if the acceptable moisture content of a product is decided prior to purchase or shipping. Fees can be levied on companies that do not ship at the agreed moisture level or the product could be rejected outright. Finally, since moisture content contributes significantly to the weight of such materials, properly drying a substance to acceptable limits before it is transported can dramatically reduce shipping and disposal costs. Simplifying Moisture Measurement Although traditional laboratory and online based moisture measurement techniques are useful in the right settings, they have lacked the simplicity and flexibility required for frequent spot checks. One common test is Loss on Drying, which measures the total material weight change after drying. However, such tests typically require a sample to be prepared and brought back to the lab. The test takes at least 15 minutes to several hours to perform, which is too slow when more immediate measurements are required. It also requires the sample to be altered or destroyed. The other common test is a Karl Fischer (KF) test. This procedure calls for chemical reagents to be added to the sample to separate the water from the remaining product. The water removed is then compared with the initial mass or volume. Samples are generally small, making the assumption that a large batch is homogenous. Also, since the chemical reagents need to be used, skilled personnel are required to determine the initial parameters, confirm that the system is properly calibrated and maintained and, at times, required to actually conduct the tests. Disposal of the reagents and waste can be subject to substantial documentation and costly handling. As a result, secondary test methods have typically been used to deliver faster results. This type of test uses an indirect method and a single conversion to achieve accurate results. Secondary measurement techniques are routinely accepted as equal to the gold standard method. Examples are speedometers, common infrared and liquid thermometers and most pressure gauges. If there is a disadvantage, it is that the instrument must first be calibrated to ensure accurate results. In some cases, calibration could only be performed by trained staff familiar with the equipment. In response, industry innovators have developed a simplified approach that allows even less-trained personnel to take

Cleaning or Etching Items with Unique Geometries Requires Specialized Expertise Cleaning or Etching Items with Unique Geometries Requires Specialized Expertise Cleaning, an integral part of many manufacturing and maintenance processes, is often critical to the performance of a broad range of technologies in the semiconductor, defense, MEMS, photonics and biotech industries. “Cleaning,” in this case, refers to the use of agents such as solvents, acids or bases to remove unwanted particulates and other contaminates from products ranging from optics to semiconductor and electronic devices. It also refers to the etching process utilized in semiconductor fabrication, where the “cleaning” is the precision removal of thin layers of material. Today, many of these processes are relatively standardized. Semiconductor wafers, for example, are produced in several sizes and processed the same way, no matter the type. However, for products with non-standard geometries, shapes, sizes and even weight, cleaning takes on a new dimension: figuring out how to optimally get each item in and out of the equipment at each stage of processing. Within this category are a potpourri of items such as optical lenses for the world’s largest telescopes and high-energy lasers, the crystals used in nuclear sensors or guidance systems, glass substrates, MEMs devices, probe sensors, medical implants, chemically machined subcomponents, etc. With these types of items, creative solutions must be employed to load items in and out of what is typically a multi-stage process. This can include utilizing automated gantry robots, machined fixtures and loading carts. Careful consideration must also be given to the orientation and, potentially, the rotation of the item after it enters the process baths. “We are not just concerned with the cleaning equipment, but also how to get the products in and out of that tool,” says Louise Bertagnolli, president of JST Manufacturing (Boise, ID), a specialist in wet processing and precision cleaning equipment. “The handling of non-standard items of various geometries, sizes and weights is a factor that most customers don’t think about,” adds Bertagnolli. “Instead, they focus almost solely on the cleaning process – the temperatures and chemical concentrations. Yet, product handling can impact the amount of chemicals required, processing time and even quality of cleaning.” Lifting, Transporting with Gantry Robots Companies that choose to automate a cleaning process usually do so to ensure the repeatability of cleaning results. This means precisely controlling the measurement and dispensing of the cleaning agents and rinsing solutions. It also means providing the systems and tools necessary to transport the items from one bath to another. For this, robots are often used to lift and transport items to multiple stations or modules. At companies like JST, this necessitates working closely with automation partners such as Bosch Rexroth (Charlotte, NC) to develop cleaning stations using linear motion and electric drive and control technology. In a recent project the two firms worked together to create an automated system for cleaning silicon chunks to the extreme purity of 11N to meet requirements for the manufacture of semiconductor chips. The project entailed building a cleaning line 138 ft. in length and incorporating multiple gantry robots. The throughput volume requirement for the chunks was four tons for every 22-hour shift. To accomplish this, JST had to develop a unique basket system to transport the material throughout the process. To provide for such a long cleaning system, JST engineered and built it in two units. In the 24-ft-long unit, baskets of chunks are manually loaded through an auto-door. Then two-axis robots cycle the baskets through five acid etch baths and two rinse baths arranged in a single row down the length of the second unit. In some cases, gantry robots are the only solution, particularly for heavy items that may be too much for workers to handle safely. Bertagnolli has seen products that must be lifted that exceed 50, even 100 lbs. In a project for Lawrence Livermore National Laboratories’ National Ignition Facility (NIF), JST was charged with figuring out a solution for handling thousands of heavy optical lenses. NIF operates one of the world’s highest-energy laser systems, which consists of 192 laser beams that can focus nearly two million joules of energy. Each of the 192 beams is supported by up to 50 lenses. “If these lenses were not as clean as possible then we would start to degrade the performance of our laser,” explains Patrick Williams, NIF optics maintenance manager. “The optics are heavy and rather large, so we don’t want to handle them a lot,” adds Williams. “JST suggested that there might be an easier and more cost-effective way to transport, clean and inspect the optics. They came back with an original design, and then we tweaked it into a system that has worked for over 16 years.” One of the innovations in the NIF cleaning tool, which was a tank-like configuration, was to eliminate the need to move the optics to different locations to perform the washing, rinsing and drying functions. In lieu of moving the optics, all cleaning, rinsing and drying is done in one tank. The chemistries move, not the product. Machined Fixtures Bertagnolli says another important element to consider is the fixturing – the devices that hold or position the products being processed. Single or multiple item fixtures are typically designed and machined to fit the specific application. Because precision cleaning equipment is largely a task involving metal fabrication and machining, suppliers like JST can also provide custom designed fixtures. Well-designed fixtures can even accommodate quick-change inserts that allow it to be re-used for other parts. Orienting the part Attention should also be given to optimizing the orientation of the part if it has blind holes or other geometric features facing up that can hold chemistry when lifted out. The same holes, if horizontal, can create unwanted bubbles or air pockets. For these reasons, it might be necessary to design a solution that orients the part in certain direction and then rotates it later in the process. Even if no blind holes are involved, etching the entire surface of a part may

Preventing Tool Theft on the Jobsite Preventing Tool Theft on the Jobsite Vault-like jobsite boxes are ideal for deterring theft of tools and supplies, but must be designed with attention to seemingly “small” details that increase security to keep thieves at bay According to some insurance companies, tool theft on construction sites cost over a million dollars each year. But, the National Equipment Registry (NER) places that figure even higher, at over a billion dollars annually. The NER figure may be more accurate as theft of smaller power tools and equipment are often not reported to insurance. Sometimes, going through the claims process with the insurer seems more bother than it’s worth. But, replacing stolen tools, even less expensive hand tools, adds up and eats away at a company’s profits. Replacement costs aren’t the only expense, however. Time and productivity lost due to tool theft must also be considered. When workers don’t have tools readily available, it decreases efficiency and potentially adds time for job completion. With many jobs, missing a deadline can mean penalties, fines and lost contracts. Tools aren’t the only items subject to construction jobsite theft. Materials used in the installation of various systems are also at risk. For example, copper products used in plumbing and electrical systems are tempting targets for theft. Other metals such as brass and aluminum are often stolen and sold for instant cash as well. How to prevent tool theft There are several methods contractors and site owners use to help deter tool and equipment theft. Some of these are fencing, signage, site lighting and video monitoring. In some cases, security guards patrol the area. However, there are inherent problems with these measures. While they seem proactive, the contractor is relying on a third-party solution to deter theft. If thieves want to steal tools and equipment, they will find a way to thwart these safeguards. In fact, according to a report by Great American Insurance Group, thieves have studied construction industry practices and know when to strike. An estimated 90% of thefts take place between 6 p.m. on Friday and 6 a.m. on Monday. Measures must be taken to prevent these weekend thefts, when construction job sites are often unattended. The best way to do that is using sturdy, job site tool boxes and cabinets. Job boxes are the construction site equivalent to a bank vault. During work hours, they keep the tools organized and accessible. After hours, they secure the contractor’s tools and supplies. Designed to withstand all weather conditions, jobsite storage boxes can be left onsite for extended periods of time. What to look for in a jobsite box Careful consideration must be given to purchasing a jobsite tool box. Low quality, less expensive versions can be purchased from home improvement outlets and some discount stores. However, these are not adequate. For a professional contractor, they prove to be anything but economical. According to Matt Jones, heavy-gauge sheet steel and reinforcements are a must for box floors and sides. LEC Products is a fabrication company, specializing in job site boxes and cabinets. They use 14- and 16-guage sheet metal for walls, doors, lids, and shelving. The thicker gauge metal also adds some extra weight to the finished product. In effect, it becomes an unseen deterrent to tool theft. Thicker steel also stands up better to the rigors of construction site use. A box will be subjected to a lot of wear and tear onsite and the heavy gauge steel and reinforcements protect the contractor’s investment by securely housing his tools. The type of steel used in manufacturing makes a difference as well. Hot-rolled steel is more malleable than cold-rolled and allows for more complex bends without weakening the steel when making box components. Design characteristics that enhance security and usability Many contractors chain their job boxes to support beams for added security. This usually means looping the chain through the handles. A better design includes a key slot in the back. After looping the chain around the pole, both ends of the chain are passed through the slot and secured from the inside. This eliminates an exposed padlock, often the weakest link. Several boxes can be ganged together as well. Removing the center trunnion in cabinet style boxes allows easy removal and replacement of longer items. Workers are more likely to store these items and not leave them lying around. However, if choosing this option to further secure tools, be sure to inspect the latch system first. It should be fitted with a three-point latching mechanism such as the one LEC Products uses. A hook secures doors together, while vertical rods pass through the top and bottom rails. Furthermore, ensure the locking system is robust. A hasp and padlock is not an option for security. The padlock is too easily defeated by bolt cutters or torches. The best system utilizes a thick steel plate cover to protect the padlock while still permitting easy use of the key. Caster attachments designed for safety and security All commercial job site boxes are designed to accept casters. This allows the contractor to move boxes to a convenient onsite location without forklifts or other powered equipment. But, most casters must be bolted onto the box. During transportation, this can cause box instability on the trailer. Extra care must be used when securing the box or cabinet. LEC Products’ casters are bolted onto steel plates, which are then slid into receivers built into the feet of the job box. This allows the boxes to be transported to the site safely, directly contacting the trailer bed surface. Once on site, the boxes are removed from the trailer and while the box is still suspended, the casters are quickly slid into place. Once they are rolled into position, the box ends can be lifted slightly, and the casters removed for storage in the job box. An added benefit is that one set of casters can be used for several job boxes, saving money. Save money on purchase,

Fastener Manufacturers Improve ‘Drivability’ with Unique Coatings Fastener Manufacturers Improve ‘Drivability’ with Unique Coatings Specialty coatings can provide fastener manufacturers with new products and a competitive edge Since cordless tool battery life is a serious concern for pros and DIYs, a growing number of fastener manufacturers are addressing the issue with unique coatings that dramatically increases the “drivability” of nails and screws. This, in turn, minimizes the amount of power used by cordless tools, extends the battery life and increases productivity since fasteners can be fixed faster and in higher volume before the battery must be changed out or recharged. Drivability can also impact gas-actuated fastening systems that utilize fuel cells, coupled with batteries, to drive framing nails, finishing brads or screws without having to connect to an air compressor or power cord. The fuel cells, which can cost as much as $15 at big box stores depending on the brand, are typically advertised as being able to driving 1,200 nails. By improving drivability of framing nails, a more economical and efficient 2,000 nails could be achieved per fuel cell, for example. According to Dan Chin, President of Universal Chemicals & Coatings (Unichem), this was the specific goal of one fastener manufacturer that sought his company’s help in creating a specialty coating that would dramatically improve the drivability of nails. Unichem is a custom coating and adhesives formulator that has worked with fastener manufacturers on these types of issues. The manufacturer’s goal, says Chin, was to be able to market the gas-actuated framing nail gun’s ability to drive a higher number of nails per fuel cell to differentiate it from the competition. “The goal was to improve what the company called ‘ease of drive’ by 25%, which is a huge number,” says Chin. “In doing so, more framing nails could be driven flush with one fuel cell.” To shoot a nail, fuel cell-powered nail guns inject a small amount of fuel along with compressed air into a chamber. A battery-supplied spark then causes a tiny explosion, which drives home the nail. Manufacturers of cordless framing and finishing guns often market unit-specific nails or screws. These consumables generate significant ongoing revenue. Given the competition in the space, offering a product with a promotable differentiator is even more critical. The challenge facing Unichem was to create a custom coating for the nails that improved drivability without allowing it to be easily removed. “You can create a coating that increases the lubricity or ‘slipperiness’ of the nail so it goes in easily, but then it must act like an adhesive once in so it cannot be easily taken out,” says Chin. Unichem’s chemists successfully figured out a coating formulation that improved nail drivability by 25%, while meeting required anti-withdrawal properties. “The specialty coating allowed the customer to re-launch the product and market it as incorporating new, improved technology,” explains Chin. “They were able to increase their revenue and were very successful with it.” The coating also potentially increases the number of nails that could be driven on a single, full battery charge, a high priority for cordless tool manufacturers and users. Whether a pro wields a framing nailer at a construction site or a DIYer uses a finish nailer to install moldings or baseboard, no one wants to interrupt the job to change out, or recharge, a dead battery. The same is true for anyone using a cordless screwdriver, drill driver, or impact driver. To address this issue, various strategies have been employed to extend battery life. Some include moving to more powerful, longer-lasting lithium batteries along with techniques to avoid overcharging. Instead, Chin suggests forward thinking fastener manufacturers consider custom coatings that help to speed jobs and maximize cordless power tool life in the field. “In a competitive market like fasteners, coatings can be used to create innovative new products with a clear-cut differentiation from the competition,” says Chin. For more information, contact Unichem at 1975 Fox Lane, Elgin, IL 60123; or Call: +1 (847) 931-1700, Fax: +1 (847) 931-1799; email: sales@unicheminc.com or visit online at www.unicheminc.com

Schools Are Transforming Walls into Versatile, Functional Surfaces Schools Are Transforming Walls into Versatile, Functional Surfaces Colorful fabric wall coverings display class work, serve as bulletin boards, and absorb noise to enhance learning environments A growing number of K-12 schools, colleges and universities are transforming their classroom, lecture hall, auditorium, hallway and dorm room walls into vibrant, multipurpose, functional surfaces by installing unique fabric wall covering systems. By adding these wall systems, they are not only personalizing and enlivening drab spaces, but also improving the learning environment while eliminating a major source of routine maintenance and re-painting. These systems are essentially constructed of a fabric covering that is stretched over a durable backing material using a mounting frame. Once installed, the fabric wall is rugged enough to withstand considerable impact and abuse – and versatile enough to deliver a variety of key benefits for both students and administrators. One benefit is that fabric wall coverings are “tackable,” meaning students can staple or tack a virtually unlimited number of notices, announcements and banners in hallways and common areas without the surface degrading. In classrooms, tackable surfaces are ideal for posting classwork and recent projects. In dorm rooms, tackable fabric walls allow students to tack up personal items and posters to liven up their living spaces without destroying the walls. Another benefit is that these same systems also improve the learning environment by providing noise reduction barriers. Because the core of the wall coverings absorbs noise and reduces echoes bouncing off of bare walls, students are able to focus with fewer distractions from exterior noise. Already installed in some of the biggest and most well-known K-12 schools, colleges and universities throughout the United States, the fabric wall coverings provide another significant advantage from a maintenance perspective by reducing the need to constantly maintain, patch and re-paint interior walls. Orange Lutheran High School Like many schools, Orange Lutheran High School in Orange, CA displays student work in classrooms to inspire achievement. Founded in 1973, it is a comprehensive private Christian co-educational college preparatory high school for grades 9-12. “A lot of teachers like to display student work as inspiration, and some teachers staple student work or study aids to the classroom walls from floor to ceiling, which can require some touch up,” says Brad Heinecke, a maintenance technician at Orange Lutheran High School. However, when staples, tacks or tape are used as a fastening method this inevitably takes a toll on painted walls. This necessitated repainting each classroom every 2 to 3 years. To do such work including touch-up in this and other areas, the school once employed a full-time painter. The first rooms to get fabric walls were several foreign language classrooms. The initial plan, says Heinecke, was to just install a large bulletin board, but there were so many items being posted in each classroom that the plan became more ambitious. So the high school opted instead to install fabric wall coverings on at least two of the walls in these classrooms using 5’ high panels from Fabricmate Systems, a global supplier of wall surface solutions. According to Heinecke the school was sold on the concept after conducting some of its own scratch tests on the fabric as well as stapling tests on the backing using samples provided by the supplier. He says Fabricmate even brought in samples of fabric and invited everyone evaluating to try and stain it with various food products or substances. When Fabricmate washed and tested the fabric no stains remained. Installation was easy as well. With the help of one other person, Heinecke installed the system. “Once you get the process down, it goes up pretty quick,” he says. Heinecke says the fabric covered wall system is holding up extremely well in the classrooms. “We’ve been really happy with the fabric wall covering system so far,” says Heinecke. “The walls in those classrooms probably had 500 staples put in them so far this year with no noticeable damage. The backing even withstands the impact of hammer type staplers.” Orange Lutheran has since installed additional fabric wall coverings in an enclosed high traffic hallway and designated it as the spot for students to post items. “We had a lot of issues with painted walls, with kids putting up posters and everything,” says Heinecke. “We now have the fabric wall coverings in a couple of hallways. That is where they staple all their announcements, banners, and posters.” As for the future, Heinecke says the school just ordered more of the fabric wall coverings for additional classrooms. Administrators are also planning to add a 2’ border beneath the current fabric wall in the main hallway to increase the tackable space and add wall protection to eliminate the need for re-painting. “Everyone is seeing how great the wall coverings are, and are requesting installation this summer,” says Heinecke. Improving Communication Universities are on board with the concept as well. Titus Botezan, President of Titus Enterprises, a school contractor based in California, says he has installed Fabricmate wall coverings at the University of Southern California (USC) in large common areas such as study rooms and community centers. Such rooms typically involved the installation of more than 40 linear feet of tackboard. “Students and teachers like how the fabric wall coverings allow tacking up items in virtually any configuration with no damage or mess,” says Botezan. The fabric wall coverings are widely used in dorm rooms, where students enjoy the creativity of being able to tack up and arrange inspirational photos, posters, or personal items on the wall. When used on the outside dorm room doors, they also make a convenient place to post memos, reminders, or invitations. When used in dorm room common areas, they become community bulletin boards, or can even serve as decorative themed graphic panels. Botezan says he is aware of a recent project at UCLA, where fabric wall coverings were installed in hundreds of dorm rooms. The University of Wisconsin, New York University and Kansas State

Continuous Airborne Legionella Detection Reduces HVAC Health Risk Continuous Airborne Legionella Detection Reduces HVAC Health Risk Protecting Facilities from Sugar Dust Explosions 24/7 monitoring system for airborne Legionella caused by drift from cooling towers provides detection and confirmation in hours, enabling an immediate, corrective response To safeguard the health of building occupants, nearby personnel and even individuals innocently passing nearby, HVAC professionals that install chiller systems with cooling towers are seeking solutions that reduce the chance of spreading the potentially deadly Legionella bacteria that causes Legionnaire’s disease. Fortunately, new continuous monitoring devices are now on the market that can detect airborne Legionella and provide automatic notification within a matter of hours. This not only eliminates waiting days for outside lab results, but also enables a proactive response that dramatically reduces the risk of a devastating outbreak or costly litigation. Legionnaire’s Disease in HVAC Systems Legionnaire’s disease is a severe, even fatal, form of pneumonia caused by the bacteria. According to the Centers for Disease Control and Prevention (CDC), 6,000 annual cases of Legionnaires disease were reported in the United States, with one out of 10 dying. Although Legionella is found naturally in bodies of water and in the majority of building water systems, the highest risk is when the bacteria becomes airborne in mist, spray or droplets that can be breathed into the lungs. This is where cooling towers play a critical role. In HVAC, cooling towers are often used in conjunction with chillers for large building cooling systems. A recent CDC study involving 196 cooling towers nationwide found that 84 percent contained Legionella DNA in the water. The problem is that cooling towers by their very nature use evaporative methods to rapidly cool the water in the system. This can cause “drift” – a fine mist – that can travel long distances based on wind speed, building height, and cooling tower location. For buildings where cooling towers are installed on roofs in nearby vicinity of fresh air intake systems – as is often the case – this could expose the building’s occupants to the bacteria. It can also pose a risk to nearby building personnel conducting maintenance. When drift is considerable, it can affect individuals in nearby buildings, parking lots and even on the street as well. Reports show that airborne Legionella can travel as far as one mile in some instances. Such was the case in recent national news that Disneyland had to shut down two cooling towers, located over 100 feet from areas accessible to guests that were ultimately found to have Legionella. According to the L.A. Times, in the Legionnaire’s disease outbreak, 11 of 15 people infected had visited the park, and four had not – including two that died. These, and other incidents, are serving as a wakeup call for HVAC industry professionals that utilize cooling towers with chillers. Continuous Monitoring for Airborne Legionella Today simple, economical, automated systems can provide continuous monitoring for airborne Legionella. Automatic notification to cloud networks and mobile devices warn of initial detection of the bacteria, followed by full confirmation in a matter of hours. This stands in stark contrast to the days or even weeks shipping samples to off-site labs before receiving results. Current testing methods typically involve infrequent (i.e. monthly or quarterly) tests using settle plates that contain culture media exposed to the air that are then incubated or impactors that must be sent to a third party lab for analysis. For these types of tests, it can be three days before the results are available. Tests are also often performed on the water itself, which can demonstrate the presence of Legionella but not determine if there is any airborne risk. Instead, continuous monitoring devices such as PathogenAlert’s RAPID (Rapid Airborne Pathogen Identification and Detection) Reader System can detect and confirm the presence of airborne Legionella within hours of sampling. The small wireless device mounts anywhere and operates by automatically sampling the air in cooling towers, chillers, ducts, or other high risk areas every five minutes (or any other time frame specified) on a 24/7 basis. Air is drawn in and flows across the cartridge, allowing any Legionella microbes to settle on a nutrient rich site where it then begins to grow. To detect pathogen growth, the device uses optical measurement and laser technology, along with electronic digital signal processing. Inhibitors are utilized to eliminate false readings. Detection software also monitors for erratic behavior that can be caused by non-pathogenic particles, such as dust, and compensates appropriately. The RAPID Reader can be mounted just about anywhere, including on cooling towers, inside building ductwork or anywhere in occupied areas. Up to 25 sensors can be connected to a single base station with each sensor covering roughly 2,500 square feet. The cloud-based platform allows continuous, remote online monitoring of individual or multiple locations from a laptop “dashboard” that consolidates key data for review. Alarms and notifications can be sent to any mobile device. Early Detection = Early Remediation One of the primary goals of early detection is to allow existing and affective techniques to be implemented as quickly as possible to destroy Legionella bacteria.   Traditional methods are water chemicals and disinfectants.  Unfortunately, these methods are ineffective against Legionella that is already in the air.   There are, however, other options.  Germicidal UV light systems destroy Legionella in seconds.  At a specific wavelength, UV-C deactivates the DNA of bacteria, viruses, and other pathogens, which eliminates its ability to multiply and cause disease.  This tool when bundled with automated airborne legionella sensors, are effective seek-and-destroy tools for the remediation of Legionella.   With airborne Legionella and cooling towers still making news headlines together, it is time for HVAC professionals to look into automated testing and treatment options that can identify and handle the problem before it becomes a news generating event. For more info: call (901) 800-1719; email Info@PathogenALERT.com; visit www.pathogenalert.com; or write to PathogenALERT at 1931 Thomas Road, Memphis TN 38134.

Taking Batteries out of the Cost Equation for WirelessHART Networks Taking Batteries out of the Cost Equation for WirelessHART Networks Careful management of power consumption – not new battery technology – eliminates significant costs to replace thousands of batteries in wireless process field devices By Phil Hunt, president of Adaptive Wireless Solutions Wireless instruments provide critical information on physical processes such as temperature, pressure, level, flow and humidity to wireless sensing networks, including WirelessHART, ISA100, Zigbee and other 802.15.4 networks. Used to monitor the operating conditions and health of industrial equipment from engines to motors, pumps, valves, and compressors, wireless instrumentation is often used in conjunction with control systems as well as for predictive and preventative maintenance programs. Developed as an open-standard wireless networking technology, WirelessHART process field devices are most often powered by batteries. However, with hundreds – even thousands – of these devices at a single plant site, the cost and resources to replace batteries 6-8 times over the lifetime of each unit can often exceed the initial investment several times over. In addition, it places an unwanted burden on maintenance personnel while also increasing risk of injury when replacing batteries in units located in remote or hazardous areas. To address this concern, WirelessHART instrumentation is now available with batteries that are expected to last the entire life of the device. This dramatic extension of battery life is not the result of more advanced, longer-lasting power sources, but rather a careful, microsecond-by-microsecond analysis of the unit’s power consumption along with clever engineering to keep that usage to an absolute minimum. For an industry in which battery replacement is an accepted consequence of installing wireless sensor networks, removing the need for this task entirely from the equation significantly reduces the lifetime operational costs. It also removes one of the primary barriers to broader implementation for many process facilities. The cost equation To fully appreciate the escalating costs associated with battery replacement, a close examination of the numbers involved is required. Most batteries used for this type of application are expected to last 2 years, on average. With the life of wireless instrumentation estimated at 12+ years, 6 or more replacements must be purchased for each device. For this example, assume a typical battery pack is $150 and factor in an hour to change a battery at $100/hr. Considering an instrument node is $1500, by the end of its life battery replacement is twice the initial investment. Now consider the same figures at scale. Multiplied by 500 instruments, that equates to 3000 batteries at a cost of roughly $750,000 with labor included. Even at one battery the cost savings is significant, particularly in terms of time and convenience, but when you consider 500, it is very compelling indeed. There are projects that involved as many as 5000 devices. In many cases operational circumstances require batteries to be replaced sooner than every 2 years, further escalating the costs. Most instruments provide a warning when battery power is low. When this occurs, personnel proactively replace the battery before it runs out completely. In addition, there are logistical advantages to replacing batteries of similar age in nearby instruments at the same time. If you don’t change out batteries proactively, you run some risk. You could get a low battery warning from a neighboring unit a day after you leave the area. So, there can be some benefit to replacing all the batteries in an area and that means extra batteries. But that is another problem that is eliminated altogether with a lifetime battery solution. Minimizing power consumption Naturally, the amount of power consumed by a device depends on the application and the environment. What is known, however, is that wireless devices connected to networks consume quite a bit of power. However, most network communication is not as predictable and can go from dormant to large spikes in power consumption every time a signal is sent or received. When, and how much power varies, but the more frequently information is transmitted or received from the network, the more power that is burned. Making judgments about power consumption is incredibly difficult. It is not just a light bulb burning the same power second after second. It is extremely dynamic and can spike to a thousand times more consumption in one microsecond than the next. Even transmissions specified at user-defined intervals, such as for instrumentation that takes ongoing measurements, impact how long the battery will last. Some manufacturers specify battery lifetimes using readings every 32 or 64 seconds in an attempt to provide a reasonable battery life. For our equipment, which monitors the operating conditions of engines, motors, pumps, valves, and compressors, a more ideal repetition rate is every 4 seconds. If you specify every four seconds, 8-16 times the power is used. At that rate, most batteries would only last a few months, but ours last at that rate for more than 12 years. This underscores the reason that Adaptive Wireless Solutions, a manufacturer of wireless instruments, has invented new techniques to minimize power consumption and increase battery life to the full life of the instrument. As if to prove the point, the wireless instruments come with built-in batteries that are not replaceable. Replacing a unit with a fully warranted new one is preferable to buying and throwing away batteries on an old unit. To do this, advanced software and hardware was used to allow product designers to examine the power consumption of its wireless instruments on a sub-microsecond-by-microsecond basis. This provided invaluable insight, identifying areas in which power could be better conserved. The truth is that most instrument manufacturers can’t provide real numbers on power consumption and battery life, because they just don’t know the answer. At Adaptive they chose to investigate all power usage, and look for accumulative efficiencies in every facet of the device operation. Among the technologies implemented was a unique software architecture that not only turns the unit on and off automatically when not transmitting or receiving, but also turns the inherent processing on

Nation’s Largest Nonfederal Correctional System Installs Aspirating Smoke Detection in Another Facility Nation’s Largest Nonfederal Correctional System Installs Aspirating Smoke Detection in Another Facility Kern Valley State Prison is latest CDCR facility to implement aspirating smoke detection, which stops nuisance alarms, speeds detection, and requires minimal maintenance Under the guidance of the California Department of Corrections and Rehabilitation (CDCR), the largest nonfederal correctional system in the nation, Kern Valley State Prison is now joining a growing number of correctional facilities implementing aspirating smoke detection technology for fire protection. Specified by the CDCR in the bidding process, aspirating smoke detection systems draw in air through small flexible tubing secured in air ducts. The air is analyzed continuously for the presence of minute smoke particles in a remote area up to 300’ away that is inaccessible to inmates This advanced technology not only provides faster, more sophisticated smoke detection, but also eliminates several costly and troublesome operational issues associated with traditional in-duct smoke detectors. In-duct smoke detectors are prone to accumulate dirt and dust, particularly in inmate housing areas. Because the particulate can be mistakenly interpreted as smoke, it can trigger recurring false alarms. To resolve this, costly ongoing maintenance is required to access and clean each detector, a process that must be repeated when the build-up occurs again. In some prisons, the problem is so severe nuisance alarms are ignored, even disconnected. In others, maintenance can become backlogged, leaving inmates effectively unprotected except for the vigilance of guards. “Among traditional in-duct smoke detection systems, a large number of false alarms can be triggered when accumulated dust and dirt cover the sensors,” says Queen Gonzalez, a co-founder of Intelligent Fire Systems & Solutions, Inc., a Southern California based fire and life safety solutions company. Her company won the competitive public bid for the Kern Valley State Prison project involving aspirating smoke detection. At Kern Valley State Prison, a Level IV facility in Delano, CA, Gonzalez says the fire safety project entailed replacing cell exhaust duct mounted smoke detectors with an advanced aspirating smoke detection system in an inmate housing unit. The scope of this involved about 16 pods, with about 64 cells per pod, for a total of nearly 1024 cells. The aspirating smoke detection equipment chosen for the project was the VESDA-E VEA fire alarm system manufactured by Xtralis. The company is a global provider of early detection and remote visual verification of fire, gas and perimeter threats. The air samples taken through the flexible tubes located in ductwork or return air chases are transported then analyzed using sophisticated laser-based technology at a central unit located within 300’. A single VEA system supports up to 40 sample points and can be extended to 120, if needed. As a multi-channel, addressable system, the VEA central unit can pinpoint the exact location of the alarm. This can enhance safety by speeding detection, investigation, fire suppression, security management, and evacuation if necessary. Furthermore, the VEA system offers earlier detection than photoelectric technology detectors. The system is able to detect minor particles in the air much faster, even before a fire begins to flame and burn. For the project, 32 of the central units were used. These were located in a secure mechanical space behind the prison cells. According to Gonzalez, it is a relatively simple installation. After each existing smoke detector is removed, tubing connected to air sampling points takes its place. This involved running tubing in the return air chase above all the cells. The tubing, suspended on hooks, drops off into each individual duct. Another benefit of the system is that it can effectively deter inmate tampering, says Gonzalez. “If there is a way for inmates to tamper with smoke detectors, they will,” says Gonzalez. “Inmates can even block ducts so in-duct smoke detectors will not work. Any system installed must be as tamper-proof as possible.” To deter vandalism, the system will send a fault signal indicating the air flow is blocked in the event an inmate is able to cover a duct or sampling point. “Even if prisoners could see the air sampling point, they would have no clue what it is because it is so small and looks nothing like a standard smoke detector,” adds Gonzalez. Correction industry leaders also appreciate the very low maintenance required for aspirating smoke detection systems. For instance, the VEA’s aspirating tubes are self cleaning and detect any blockages or breaks in the tubing. Even if dirt, dust, or lint enters the tubing system, the filters for all the sampling points are located at the central unit in a restricted area. Cleaning the filters takes only about a minute, so there is no need for maintenance personnel to crawl into ducts to clean the detectors. The system not only stops false alarms due to dust or dirt contamination of sensors, but also can distinguish between smoke, fire, and other airborne contaminants, which further reduces nuisance alarms. Annual National Fire Protection Association (NFPA) inspections are also simplified. Unlike traditional smoke alarms, systems like the VEA do not require testing of each sample point annually at its location in the duct. Instead, the tests can be conducted at the central unit. Whether correctional facilities aim to minimize false alarms and maintenance or improve safety and security, aspirating smoke detection systems are gaining favor over traditional systems. Kern Valley State Prison joins Corcoran State Prison in California as well as Fort Dodge Correctional Facility in Iowa and Pennsylvania Correctional Facility in adopting aspirating smoke detection. Gonzalez, who is currently bidding on another aspirating smoke detection project for a prison in Arizona, concludes, “There is increasing interest in this technology, and it will only grow as more correctional facilities, engineers, and architects become aware of its benefits.” For more information, contact Xtralis at 175 Bodwell Street, Avon, MA 02322, call: UK and Europe +44-1442-242-330; D-A-CH +49-431-23284 1; The Americas +1 (619) 252-2015; Middle East +962-6-588-5622; Asia +86-21-5240-0077; Australia and New Zealand +61 3 9936 7000, email: Sales@xtralis.com rsandler@xtralis.com

How a Less than $100 Part Could Save U.S. Manufacturing How a Less than $100 Part Could Save U.S. Manufacturing For decades, the U.S. has been hemorrhaging manufacturing jobs to overseas companies. Now, a less than $100 part that some say is robbing machining operations of 20%-30% in productivity may be the key to changing that equation. With the exodus of low cost parts, U.S. manufacturers have largely been relegated to short order production runs of more complex, precision parts for the aerospace, medical devices, and Tier 2 and 3 automotive industries. For this type of work, half million-dollar CNC milling machines are programmed to cut alloys using extremely precise positioning coordinates. Every component part – from spindle to toolholder and cutting tool – is finely balanced and perfectly mated together to withstand rotation of up to twenty-thousand revolutions per minute with little or no runout. However, despite attention to almost every aspect of the machine, one critical part has largely been overlooked. Namely, the retention knob that attaches to the threaded end of tapered toolholders to engage with the drawbar, which exerts a pull force that holds the toolholder firmly in the spindle. When tightened, poorly designed retention knobs can bulge the toolholder imperceptibly at the small end of the taper, preventing full contact and proper seating of the toolholder in the spindle. This slows cutting speeds, affects tolerances and precision, shortens tool life and even increases power consumption. Yet despite widespread evidence that this occurs in the form of uneven toolholder wear patterns and simple “touch-off” tests, the industry has largely ignored the issue. Given that approximately 570,000 V-flange milling machines are in operation today throughout the U.S., and with even conservative estimates pegging productivity loss at 10-30%, the industry could be losing as much as $214 million per shift each year. “Companies purchase top-of-the-line machining centers and the most expensive cutting tools, but they completely ignore the interface between them: the toolholder and the retention knob,” says Joe DaRosa, former president at Toyota Manufacturing of Texas. While this may seem like it belongs in the category of “too good to be true,” dismissing it outright without a closer examination could be foolhardy. Even 10-20% faster machining would dramatically reduce cycle times, the machining industries’ measure of the time it takes to make each part from start to finish. Looked at from other angles, this would lower labor costs per part, allow for more competitive bids to win more jobs, increase profit margins and eliminate the need to invest in more equipment/labor to meet the same production demands. So, when DaRosa, who continues to serve as an advisor to the automotive industry, first learned about the issue with retention knobs and how it could affect productivity and tool life, he was immediately interested in learning more. “In my role as an executive, anything that could reduce costs or improve efficiency gets my attention,” says DaRosa, The flaw in the design According to John Stoneback of JM Performance Products, a manufacturer of CNC mill spindle optimization products, the problem with retention knobs began more than 40 years ago when the original milling machines were first introduced. At the time, leading American manufacturers played a critical role in developing and standardizing the first V-flange milling machines, and little attention was placed on the length of the threads in the toolholder. Stoneback says European and Japanese CNC equipment manufacturers recognized the value of a pilot to increase the rigidity of the tool, but no studies were conducted to ensure the optimal design. Much later, the world’s standards organizations fell in line and essentially adopted what had become the default standard for retention knobs. “The world standards for retention knobs are not correct because they were put in place without adequate testing,” explains Stoneback. “The current design is costing the US a fortune, mostly because the machining challenges it causes are pervasive, yet still not widely recognized as a problem.” Stoneback has an interest in this topic, to be sure. In 2009 after learning of the widespread nature of the problem, he went to work and invented a High Torque retention knob that addresses this issue. The High Torque retention knob is longer by design to reach deeper into the threaded bore of the toolholder. As a result, all thread engagement occurs in a region of the toolholder where there is a thicker cross-section of material to resist deformation. The High Torque retention knob also includes a precision pilot to increase rigidity and is balanced by design. Since even over-tightening of the High Torque retention knobs can still create a bulge, the company provides specifically calculated torque specs based on drawbar pressure. The product works with all existing toolholders including BT, DIN, ISO, and CAT toolholders from 30 taper to 60 taper. By combining the High Torque retention knob with the correct torque, spindle contact with the taper is improved to close to 100% every time. This can be verified by simple 6-step “touch off” test (www.jmperformanceproducts.com/toolholder-test.aspx). More sophisticated measurement of toolholder expansion (bulge) can also be taken using a taper shank test fixture. Janos Garaczi, president of Delta Machine Company in Gardena, Calif. decided to use the unique retention knobs for machining hard materials like titanium and other exotic alloys. The company specializes in high volume production of complex, tight tolerance parts for the medical and aerospace industries. Garaczi says the combination of equipment, High Torque retention knobs, and machining expertise has decreased cycle times as much as 40-50%, allowing Delta Machine to often outbid the competition for projects involving titanium. “At the end of the day, we are able to run [titanium and stainless steel] much faster than most machine shops,” says Garaczi. Even leading manufacturers of vertical and horizontal machining centers have begun recommending High Torque retention knobs for use on the equipment. “We have seen many situations where retention knobs have been overtightened. A guy goes to the workbench and uses a wrench and a hammer to

Stopping Corrosion in the LNG Sector Stopping Corrosion in the LNG Sector With rapid growth in wet, humid monsoon prone climates, LNG facilities and pipeline must remain corrosion resistant While corrosion is a serious issue in virtually all oil, gas, pipeline, and industrial facilities, it is a particular challenge for the liquid natural gas (LNG) sector, whose facilities must remain corrosion resistant despite rapid growth in areas prone to high humidity, rainfall, and monsoons. According to the International Gas Union (IGU) 2017 World LNG Report, global LNG trade set a record for the third consecutive year, 258 million tonnes (MT), with the greatest growth in China, India, and Pakistan, which have seasonal monsoons. In such conditions, the traditional barrier type coatings that are commonly reapplied every few years do not hold up, and often cannot be applied due to flash rusting (rust occurring within minutes or hours) caused by the wet, humid environment. The frequent required maintenance is disruptive to production, requiring blasting off the old coatings, cleaning the surface, and reapplying multiple coatings. Despite this costly process, excessive corrosion of LNG vessels and carbon steel assets can lead to leaks, fires and accidents, as well as accelerate premature replacement. Now an innovative coating approach is providing LNG facilities a long-term solution to fighting atmospheric corrosion even in monsoon vulnerable environments, while minimizing production downtime and increasing safety. As an added plus for countries like China that are concerned about pollution, the application involves no Volatile Organic Compounds (VOCs), a hazardous component of traditional paints. Protecting LNG Assets from Corrosion Southeast China’s Zhejiang province has high humidity, annual average rainfall of 1,000mm to 1,900mm (39.3” to 74.8”), and frequent typhoons in late summer. In this region, the Zhoushan LNG Project is located in the Zhoushan Economic Development Zone amid these challenging conditions. As the region’s first import LNG receiving station project in which private enterprise is the main investor, total project investment is more than RMB 10 billion ($1.45 billion). The project includes a LNG receiving station, LNG terminal, and pipe connection line, which is being constructed in phases, with completion and operation slated for 2020. It is operated by Xinao Group Co., Ltd., a wholly-owned subsidiary of ENN (Zhoushan) Liquefied Natural Gas Co., Ltd. However, in phase I of the LNG project, traditional corrosion protection, which typically involves applying polymer paints and rubber type coatings, was ineffective due to very rainy, humid, windy conditions. Such coatings, in fact, often could not be applied because the humidity level was too high and the steel kept flash rusting. While such methods can create a physical barrier to keep corrosion promoters such as water and oxygen away from steel substrates, this only works until the paint is scratched, chipped, or breached and corrosion promoters enter the gap between the substrate and coating. Then the coating can act like a greenhouse – trapping water, oxygen and other corrosion promoters – which allows the corrosion to spread. Traditional solvent-based paints also posed another problem. When the solvents evaporate, they release VOCs, which are a source of air pollution, and contain a variety of chemicals linked to adverse health effects. For this reason, China has moved toward coatings that eliminate organic solvents, such as water-based paints. In response, when the Xinao Group sought long term, external, corrosion protection for two fire fighting water tanks, the company turned to EonCoat, a spray applied inorganic coating from the Raleigh, North Carolina-based company of the same name. EonCoat represents a new category of tough, Chemically Bonded Phosphate Ceramics (CBPCs) that can stop corrosion, ease application, and reduce production downtime even in very wet, humid, monsoon susceptible conditions. In contrast to traditional polymer coatings that sit on top of the substrate, the corrosion resistant CBPC coating bonds through a chemical reaction with the substrate, and slight surface oxidation actually improves the reaction. An alloy layer is formed. This makes it impossible for corrosion promoters like oxygen and humidity to get behind the coating the way they can with ordinary paints. Although traditional polymer coatings mechanically bond to substrates that have been extensively prepared, if gouged, moisture and oxygen will migrate under the coating’s film from all sides of the gouge. By contrast, the same damage to the ceramic coated substrate will not spread corrosion in LNG projects because the carbon steel’s surface is turned into an alloy of stable oxides. Once the steel’s surface is stable (the way noble metals like gold and silver are stable) it will no longer react with the environment and cannot corrode. Visible in scanning electron microscope photography, EonCoat does not leave a gap between the steel and the coating because the bond is chemical rather than mechanical. Since there is no gap, even if moisture was to get through to the steel due to a gouge, there is nowhere for the moisture to travel. This effectively stops atmospheric corrosion of LNG carbon steel assets. The corrosion barrier is covered by a ceramic layer that further resists corrosion, fire, water, abrasion, impact, chemicals, and temperatures up to 400 °F. Beyond this, the ceramic serves a unique role that helps to end the costly maintenance cycle of replacing typical barrier type coatings every few years. “In LNG installations, including receiving stations, terminals, and pipeline, if both the ceramic layer and the alloy layer are ever breached, the ceramic layer acts as a reservoir of phosphate to continually realloy the steel,” explains Merrick Alpert,” President of EonCoat. “This ‘self heals’ the breach, depending on its size, and stops the corrosion if necessary. This capability, along with the coating’s other properties, enables effective corrosion protection for the life of the asset with a single application.” The Xinao Group has successfully coated one Zhoushan LNG Project fire fighting water tank with the spray applied inorganic coating, which is compatible with a wide range of commonly used topcoats, and the other tank is expected to be completed in January 2018. Because of the ceramic coating’s multiple layers of

Stopping Corrosion Under Insulation in Global Oil and Gas Facilities Stopping Corrosion Under Insulation in Global Oil and Gas Facilities When traditional corrosion protection fails, a new approach can dramatically extend life in upstream, midstream, and downstream applications Corrosion Under Insulation (CUI) is the root cause of many of the global petrochemical industry’s most serious problems including forced shutdowns, lost production, early repair and replacement, as well as safety and environmental consequences that can cost millions of dollars per incident. CUI, which involves the corrosion of vessels or piping beneath insulation due to water penetration, is insidious because it can remain undetected until the insulation is removed for inspection or leaks occur. Water penetration can result from many causes including monsoons, rain, flooding, wash downs, and sprinkler systems, as well as exposure to steam, humidity, or frequent condensation and evaporation of atmospheric moisture. From upstream wells, risers, drilling rigs, or offshore platforms, to midstream pipelines, storage, and liquefied natural gas (LNG) terminals, to downstream refineries, fighting CUI and major corrosion has been an uphill battle and a major cost in the operation of oil and gas facilities, according to NACE International’s “International Measures of Prevention, Application and Economics of Corrosion Technology (IMPACT)” study. Fortunately, even when traditional coatings have allowed CUI and corrosion to occur, a new approach can stop the corrosion to dramatically extend facility and equipment life in oil and gas industry applications. Stopping Existing Corrosion and CUI Traditional corrosion protection typically involves applying polymer paints and rubber type coatings. Such methods create a physical barrier to keep corrosion promoters such as water and oxygen away from steel substrates. However, this only works until the paint is scratched, chipped, or breached and corrosion promoters enter the gap between the substrate and coating. Then the coating can act like a greenhouse – trapping water, oxygen and other corrosion promoters – which allows the corrosion to spread. Some of the world’s largest petrochemical companies, including China Petroleum & Chemical Corporation, however, are finding success with a new approach toward stopping CUI and corrosion. China Petroleum & Chemical Corporation, commonly known as Sinopec Corp., is one of the largest integrated energy and chemical companies in the world, with upstream, midstream and downstream operations. In Sinopec’s Jianghan Oilfield projects, located in China’s Jianghan Plain in Hubei province, there are numerous facilities for oil and gas extraction, transport, and storage. However, with Hubei’s sub-tropical monsoon climate, CUI and corrosion are serious issues that shorten equipment life and require excessive maintenance. In this environment, traditional coatings have been ineffective, and stopping corrosion that is already underway is often the last resort. To extend production and the service life of assets already experiencing serious CUI or major corrosion, on two sample projects Sinopec turned to EonCoat, a spray applied inorganic coating from the Raleigh, North Carolina-based company of the same name. EonCoat represents a new category of tough, Chemically Bonded Phosphate Ceramics (CBPCs) that can stop the corrosion, ease application, and reduce production downtime even in very wet, humid, monsoon prone conditions. In contrast to traditional polymer coatings that sit on top of the substrate, the corrosion resistant CBPC coating bonds through a chemical reaction with the substrate, and slight surface oxidation actually improves the reaction. The surface of steel is passivated as an alloy layer is formed. This makes it impossible for corrosion promoters like oxygen and humidity to get behind the coating the way they can with ordinary paints. Although traditional polymer coatings mechanically bond to substrates that have been extensively prepared, if gouged, moisture and oxygen will migrate under the coating’s film from all sides of the gouge. By contrast, the same damage to the ceramic coated substrate will not spread corrosion because the carbon steel’s surface has been chemically transformed into an alloy of stable oxides. Once the steel’s surface is stable (the way noble metals like gold and silver are stable) it will no longer react with the environment and therefore cannot corrode. Visible in scanning electron microscope photography, EonCoat does not leave a gap between the steel and the coating because the bond is chemical rather than mechanical. Since there is no gap, even if moisture was to get through to the steel due to a gouge, there is nowhere for the moisture to travel. This effectively stops atmospheric corrosion and CUI on carbon steel assets. The corrosion barrier is covered by a ceramic layer that further resists corrosion, water, fire, abrasion, impact, chemicals, and temperatures up to 400 °F. Beyond this, the ceramic serves a unique role that helps to end the costly maintenance cycle of replacing typical barrier type coatings every few years. “CUI is the silent killer,” explains Merrick Alpert,” President of EonCoat. “The insulation creates a terrarium on the steel in which corrosion is guaranteed to occur if traditional coatings are used. And the insulation then hides the corrosion from being detected until it’s too late.” Sinopec’s first sample project using the CBPC coating involved addressing CUI on a 500 cubic meter petroleum storage tank in an oil-extraction facility in the Jianghan Oilfield. While the storage tank’s original coatings were wrapped beneath a mineral wool insulating layer, due to rain, condensation, and moisture invasion through the damaged insulating layer, these coatings had failed, allowing CUI in a number of areas. After peeling off the insulating layer, the metal surface underneath was prepared by sandblasting, then the CBPC coating was applied. The application has effectively stopped the CUI issue and is expected to extend the storage tank’s functional life for years to come. After the success of the first project, Sinopec opted to utilize the CBPC coating to address serious corrosion on a container-type water injection pumping station in another Jianghan Oilfield facility. Because of the pumping station’s outdoor location with very high saline alkali content soil, along with a very humid container environment, shutdown for corrosion maintenance was typically required every three years. A traditional three coat system was routinely used to maintain corrosion

Cold Storage Distributor Optimizes Rack to Continue Expansion Cold Storage Distributor Optimizes Rack to Continue Expansion Rugged drive-in rack designed to the application enhances longevity and access To meet retailer demand for efficient cold chain distribution east of the Mississippi River, Manfredi Cold Storage has had to keep expanding its Kennett Square, Pennsylvania facility. Just recently it expanded the facility by 70,000 sq. ft., for 400,000 total sq. ft. of cold storage space, and already plans are in the works for future expansion. The distributor handles fruit, vegetables and food stuffs from 22 countries, at 0-55°F temperatures, in its facility that provides retailers with wireless, real-time inventory and access. In order to keep such continued growth on track, however, effective operation has required the use of exceptionally rugged drive-in rack, designed to the application by Steel King Industries, according to Rob Wharry, the facility’s Director of Operations. “About 150-200 truckloads of product move in and out of our storage everyday, about 25,000 pallets, so the drive-in rack needs to be very durable and accessible,” says Wharry. “The product has to go out quickly and efficiently to grocery stores, club stores, distribution centers, and the food service industry.” Withstanding a Tough Environment Drive-in rack enables storing up to 75% more pallets than selective rack and is ideal for high-traffic and cooler/freezer installations. With drive-in rack, forklifts drive directly into the rack to allow storage of two or more pallets deep. But because forklifts drive directly into the rack, they tend to take more abuse than other rack structures. In cooler and freezer applications, the rack must withstand some of the greatest forklift abuse in warehouse material handling due to the confined space, slick surfaces, and cold temperatures that slow driver reflexes and make impact more frequent. “We’re in and out of rack with heavy pallets and equipment so many times a day,” says Wharry. “It’s a fact of life that sometimes forklifts will run into the rack, so it just needs to be able to stand up to the daily use.” Looking to optimize the rack’s durability and operation, the cold chain distributor turned to Steel King Industries, a storage system and pallet rack manufacturer. “We had used several different rack manufacturers previously, but have pretty much exclusively used Steel King for the last 13 years because they make a very rugged product that is specifically designed for our application,” says Wharry. In the most recent expansion, about 4,000 pallets of refrigerated storage capacity were added. For this, Manfredi Cold Storage chose SK3000® pallet rack, a rugged bolted rack with structural channel columns, by Steel King. A number of rack features are helping the distributor to meet its strength, durability, and maintenance goals. Compared to typical racking, the pallet rack constructed of hot-rolled structural channel column with full horizontal and diagonal bracing offers greater frame strength, durability and cross-sectional area. All Grade-5 hardware provides greater shear strength, and a heavy 7-gauge wrap-around connector plate ensures a square and plumb installation with a tighter connection and greater moment resistance. The drive-in rack also includes a number of features that enhance ease-of-use and safety. The drive-in load rail construction includes: structural angle rails that “guide” pallets for ease of use; flared rail entry ends to allow easy bay access; space-saver low profile arms that increase clearance and decrease possible product damage; welded aisle-side load arms that eliminate hazardous load projections into aisles; welded rail stops that prevent loads from being pushed off and increase safety; and 2” vertical adjustability of the bolted rack, which allows for a variety of configurations for current or future products. “The heavy rub rail inside the rack helps to guide the pallets in,” says Wharry. “The flared rail entry makes it easier to put pallets in and to take them out of the upper positions.” For extra protection and reinforcement against forklift impact, a guard on the front of the rack’s first upright was added. The double column, welded angle column protector is designed for heavy pallets and provides additional strength. According to Wharry, their drive-in rack vendor was also willing to accommodate their needs in other ways as well. “Our operation is a little different than a typical storage customer because we’re dealing with lots of different sized products, so we had a very specific design in mind,” says Wharry. “Everything is specific to our application: rack height, width, pallet loads, and how we utilize it.” The rack openings are about 12-16” taller than a standard rack opening to allow the use of very tall pallets, he says. Additional adjustments to the rack include the specific implementation of guards, heavy rail, and how it is anchored to the floor. “Other companies can build to order, but Steel King is more willing to work with us to design a system that gives us exactly what we need,” says Wharry. While Manfredi Cold Storage’s latest expansion of its Kennett Square facility will help provide retailers with greater cold chain distribution coverage and speed, there is still room to do one more expansion of similar size at the site, says Wharry. With continuing growth expected, however, the distributor is already planning to start the construction of a brand new cold storage facility in southern New Jersey. “When the new facility is constructed, the racking set up will be just like what we have here,” concludes Wharry. “We’ve determined what works for us and our customers, and now it’s just a matter of ramping up.” For more info on optimizing warehouse storage and production, contact Steel King Industries, 2700 Chamber St., Stevens Point, WI 54481; call 800-826-0203; email: dheemstra@steelking.com or visit www.steelking.com

5 Tips for Selecting and Optimizing Wet Processing Equipment 5 Tips for Selecting and Optimizing Wet Processing Equipment Subtle modifications to standard wet processing equipment can make it more flexible, efficient and productive. Microfabrication operations such as metal lift-off, stripping, etching, plating/coating, cleaning, and de-bonding are typically wet processing procedures. Yet, selecting the equipment to perform those procedures most efficiently and cost-effectively is often not a simple matter. In most cases, the users of wet processing equipment – whether for semiconductor, MEMS, biotech or other applications – can benefit substantially from having industry design experts review and evaluate the entire process and then recommend specific equipment solutions. Even among research and educational applications where off-the-shelf, manual wet benches may be presumed as standard solutions, such applications can gain valuable flexibility, quality or safety though relatively inexpensive customization of the apparatus design by the equipment manufacturer. Here are five tips that can help users to select wet processing systems that can optimize their processes by making them more flexible, efficient and productive. Don’t reinvent the wheel “So many wet processing equipment designs/fabrications have been standard for some time and are usually a variation of one of these standards.” says Louise Bertagnolli, president of JST Manufacturing (Boise, ID). “The l design process is a matter of choosing the most appropriate solution and then tailoring it to meet the customer’s specific application requirements.” A nationwide manufacturer of manual and automated wet processing equipment, JST’s mechanical, electrical, and chemical engineers have many years of experience in industries including semiconductors, both silicon and compound , MEMS, photovoltaics, LEDs, Flat Panel Displays , and sensors. Bertagnolli says that to optimize quality and throughput for a wet processing solution, it is advisable to consider the process involved so that a qualified, objective recommendation – including the tools and accessories – will be proposed. The equipment manufacturer should have the research and development engineers, facilities and experience to propose appropriate manual or automated process equipment plus necessary auxiliary equipment such as chemical handling, automation and product fixturing. Take a close look at fixturing In addition to determining how a customer’s process will be finalized, one of the most important elements to consider is the customer’s fixturing – the devices that will hold or position the products being processed,” says Bertagnolli. She adds that most customers are mostly concerned about the temperatures and concentrations of chemicals – things that are going to materially affect their processes – and how they are going to control those. “But at the design stage, there are also more fundamental decisions to be made, such as how the product in process should be transported to and from the wet processing tools and fixturing most efficiently in the process baths,” Bertagnolli explains. “In some cases the products may be too heavy for workers to handle, so appropriate manual or automated transporting equipment must be selected. Additionally, the wet processing chemistry must be determined: How does the chemistry arrive at the tool, and how is the chemistry extracted safely?” Fine-tune processes in the “application lab” Before finalizing a wet processing solution, visit an equipment manufacturer that has a well-equipped laboratory so that the process can be fine-tuned and tested on-site. This can ensure that the best solution is proven, and that equipment overkill is avoided. “Advanced application labs should be equipped with metrology [advanced measurement] equipment offering real-time testing results that provide the data and technologies needed to optimize the process,” explains Bertagnolli. The applications lab also enables users to control the optimization of multiple processes, and can minimize the amount of chemicals required and/or determine the tool features they need for their applications. This can save the customer money by eliminating features they do not need. Bertagnolli suggests that by utilizing 3_D modeling software such as SOLIDWORKS facilitates making modifications to best suit an application in a timely and cost effective manner. . For automated wet processing, the equipment manufacturer’s control software should be able to interface with a customer’s host system when required in order to be able to remotely operate the tool. “Also, many customers forget to determine how they are going to accommodate the new equipment in their clean room; how it will enter the facility, how much space it will occupy, how much power, water, chemicals and gases it will require, and so forth,” explains Bertagnolli. “So, the equipment design engineers will need to plan for all those factors.” Consider evolving application requirements Like other manufacturing processes, wet processes such as cleaning and etching often evolve over time. The upgrading or expansion of equipment to meet future requirements can be unnecessarily expensive and time-consuming unless the requirements are integrated into the original equipment design. “If tools are designed to be modular, there is not usually any problem in reconfiguring or expanding them,” Bertagnolli advises. “But the engineers that design the tool need to be aware of the customers’ future plans to upgrade their operations for reasons such as added throughput. All sorts of process expansions are possible, but it is very important for the design engineers to be aware of future plans at the initial design phase.” In some cases the customer’s initial wet processing equipment is semi-automated because production volume does not mandate a fully automated system. But over time the volume may increase to the point when a fully automated system is warranted in order to optimize production. “It is not unusual for a customer to come to us with a requirement, new process, new technology or something they have been doing manually and now their volume requirements have increased to the point where they need to automate because of a higher throughput requirement,” says Bertagnolli. Ensure that safety is built into the solution Although production throughput and product quality may be the highest priorities of many users of wet processing equipment, operator safety of both manual and automated equipment should also be a paramount concern, particularly when processes involve the use of dangerous chemicals. The potential for

Arizona Homeowners: Beware of Foundation Repair Misdiagnosis, Overcharging Arizona Homeowners: Beware of Foundation Repair Misdiagnosis, Overcharging An industry insider warns of sketchy sales practices and the #1 problem overlooked in approximately 80% of the state’s foundation repair jobs What Arizona homeowners don’t know about foundation problems can cost them dearly, and what they don’t know about the foundation repair business can cost them even more. The issue is that the industry is largely built on a model in which salespeople, with no engineering education and trained only by a single source supplier, are often sent out to diagnose a home’s foundation problems, recommend a solution, and close the sale in a single visit. According to industry expert Bob Brown, this model lends itself to potentially over- and under-engineered solutions ultimately paid for by the homeowner. It is also the primary reason that many foundation repair jobs are misdiagnosed, given that Arizona has unique soil conditions not seen much throughout the rest of the country. “More than 80% of the foundation issues in Arizona are misdiagnosed due to the unique clay soil conditions, combined with the arid climate, that occur here,” says Brown, president of Arizona Foundation Solutions, a Phoenix-based foundation repair company. As a foundation repair industry expert for 30 years, Brown is one of two Certified Foundation Repair Specialists (CFRS) in the state. He is also the author of the e-book, “Which Way is My Foundation Moving?” which is described as a homeowner’s guide to foundation repair. The book, which is downloadable at no cost from Brown’s web site, was written to educate homeowners on the most common problems and misdiagnosed issues to save homeowners money. Now Brown is calling for the entire industry to abandon the current sales model in favor of one in which experts – in this case, trained engineers – diagnose foundation repair issues. While this may seem obvious, this is a fundamental change in the way the industry has operated for decades. Homeowner Beware When homeowners call for a foundation repair assessment, Brown says a salesperson arrives at the home and quickly surveys the home and foundation. The salesperson then bases his or her diagnosis on superficial visual clues such as cracks in the walls and ceilings, or doors and windows that don’t open and close properly. However, most salespeople have no formal training in engineering or geology. Instead, they are trained by single-source product suppliers that offer specific solutions. In most cases, the products address only the issue of settlement. “It is easy to walk into a house and think you understand what is going on by looking around, but this can often lead to the wrong conclusion,” says Brown. During this visit, the salesperson then presents a cookie-cutter solution to the homeowner and immediately attempts to close the sale. “I’ve met hundreds of civil engineers and have yet to hear one say they can visit a home and determine an accurate foundation repair diagnosis and recommendation on the spot,” says Brown. “Yet salespeople with no engineering experience – paid solely on commission – are routinely doing so despite the obvious conflict of interest.” Brown adds that foundation repair salespeople are taught to “oversell just to be sure.” This can end up costing homeowners well over $100,000 on some repair jobs. When homeowners do not have that kind of money, a solution that is under-engineered may be offered in an attempt to make a sale. Instead, Brown advocates for a system in which engineers alone handle the diagnosis and make remediation recommendations. Although Arizona Foundation Solutions initially sends out a sales consultant, it is only to conduct an initial evaluation to determine if an engineered investigation is needed. Should an engineered evaluation be required, it needs to be conducted in a standardized, industry-recognized procedure that is overseen by a licensed, professional engineer. Arizona Foundation Solutions employs an engineering team that consists of Licensed Professional Engineers and assistants to gather the data and report back to the Engineer of Record for the project. The data gathered includes floor plans, floor level surveys, topography of the site and photo documentation of cracks or other signs of stress (defined as a Level B Investigation by the Foundation Performance Association). A Level B Investigation is the only current investigational procedure recognized by the industry. Once the Engineer of Record has reviewed this data, a report and recommendations are written and sealed by that engineer. Brown says that in some cases foundation repair companies will claim that an engineer ultimately reviews and approves the project. However, this does not mean an engineer is involved in the diagnosis or the proposed solution. Instead, it is an engineer’s evaluation that products installed, such as push or helical piers, are sufficient to support the weight of the structure. Given that virtually all products on the market can meet this standard, this type of engineering “sign-off” means little. The problem of “heave” The other problem with this model is that salespeople can misdiagnose the true root cause of the problem. This should genuinely concern homeowners because the most common foundation problems in Arizona are often misdiagnosed. It turns out that in Arizona many homes are built on fine clay soil that can become saturated with water. When this occurs, the soil either settles after it dries (causing the foundation to drop or sag) or heaves (lifts) as moisture accumulates. “Arizona soil has less clay than some parts of the country, but our state has an arid climate with soil that’s been dry for millions of years,” says Brown. “This makes homes susceptible to heave when moisture drains off the roof and has nowhere to go but under the foundation and floor slab. The wet soil then swells, which can push up the foundation/floor slab.” Both heave and settlement can cause serious damage to the home foundation and structure. This may initially appear similar to the untrained eye, although their remediation approaches differ significantly. “Cracked brickwork, floor tiles or windows can indicate either heave

A Consumer’s Guide to Digestive Health A Consumer’s Guide to Digestive Health When it comes to digestive health, too many of us prefer to suffer in silence rather than engage in an open and honest discussion about bowel movements, constipation and intestinal distress. Still, the digestive system is far too critical to both proper nutrition and health to go under the radar. When all functions as it should, we feel healthy, vibrant, and energetic. When it doesn’t, we feel sluggish, uncomfortable and even ill. There are other more serious health concerns, as well. By simply not getting enough fiber daily, for example, we are increasing our risk of hypertension, heart disease, diabetes and stroke. This should be concerning, given that most Americans consume less than half the recommended daily fiber intake, in large part due to the high sugar, highly processed foods we eat today. On top of this, we are constantly exposed to potential dangerous chemicals and toxins in our food, water and air. Our excretory system plays a critical role here too, eliminating many of these toxins. Fortunately, there are a variety of digestive health aids on the market designed to address and resolve many of these issues. However, for many consumers, sorting through the various product options can be overwhelming, even paralyzing at the point of purchase. With so many options, following some expert advice will help consumers select the most effective digestive health products from fiber supplements and detox formulations to total body cleanses. Fiber and Laxatives According to the Institute of Medicine, the recommended daily intake of dietary fiber is 25 grams of fiber for women and 38 grams for men. The problem is that most adults only get about 15 grams of fiber per day, so fiber supplements are often recommended. Dietary fiber includes the parts of plant foods the body can’t digest or absorb. Instead, it passes relatively intact through the stomach, small intestine and colon and out of the body. Many high fiber foods contain soluble and insoluble fiber, which are both beneficial for different reasons. A diet high in fiber promotes bowel health and regularity. It also can create a feeling of fullness, a useful tool in weight control. While multiple types of fiber exist, one of the most popular is psyllium. Psyllium comes from the ‘husk’ or outer coating of the psyllium plant’s seeds, says Sigmund Brzostowski, National Sales Manager at Yerba Prima, an Ashland, Oregon-based pioneer of dietary fiber and internal cleansing products since 1980. On contact with water, psyllium thickens into a gel-like substance that acts like a broom to sweep waste from the digestive tract and colon, so it does not get re-absorbed through the colon wall back into the bloodstream to recirculate in the body, explains Brzostowski. Since psyllium husk fiber provides a soft bulk and mass in the colon, it makes elimination easier and more comfortable. Psyllium also keeps the lining of the colon cleaner, since it cleans out pockets in the colon that may accumulate toxic waste material. Psyllium husk also help maintain the body’s blood sugar levels in the normal range, slowing and leveling off the release of sugar into the bloodstream. This reduces stress on the body and minimizes the blood sugar spikes and crashes that often lead to hunger pangs. Medical studies have also shown that psyllium husk can help lower high “bad” low-density lipoprotein (LDL) cholesterol levels, helping to protect against the risk of heart disease. One of the first choices consumers must make is how to take psyllium. When not in capsule form, the product is typically mixed in with water or another beverage, and even put in food. “Those who like the fiber in more of its natural form prefer whole husk psyllium,” says Brzostowski. “The powder is a finer grind, which breaks down in your system faster. The capsules are for convenience.” The quality of the fiber also matters and can impact its effectiveness. “You want to avoid lower grade fiber products that grind the whole plant, including parts that are essentially fillers,” explains Brzostowski. “Instead, check the label to make sure that the most effective parts of the plants are used, such as the psyllium plant’s seeds.” Another aspect to look out for is the sugar content, adds Brzostowski. “Some of the most well-known brands have very high sugar content, so be sure to check the label,” says Brzostowski. “Because that amount of sugar is a concern for many health-minded consumers, most of our fiber products are sugar-free.” Other choices to consider are whether the psyllium is organic, gluten free, non-GMO, or vegan. If constipation is an issue, a fiber supplement may not be sufficient by itself, says Brzostowski. In such cases, a mild laxative can be taken for a limited time. Two of the most common include senna, prepared from the dried pods of the cassia tree, and cascara sagrada, a laxative derived from the bark of the cascara sagrada tree. “Both can be effective, but most people prefer senna because it tends to be gentler on the digestive system,” says Brzostowski. Some formulations, such as Yerba Prima’s Fiber Plus Senna Powder, combine the two, along with other herbs designed to soothe the digestive system. Detox Detoxification is a popular strategy for purging our bodies of the chemicals, pesticides, heavy metals, environmental toxins, as well as drugs, alcohol, processed foods and added sugars that are so prevalent and harmful today. Many of the toxins we are exposed to are fat soluble so they are stored in our bodies. Any one of them may be safe, but cumulatively over time they burden the liver and stress the body’s detoxification capacity. One of the most effective ingredients for a safe, natural detox is bentonite, a natural volcanic clay that attracts toxins through adsorption and is taken in a solution or capsule form. The clay is not digested, but passes through the gastrointestinal tract, where it binds to toxins – including pesticides, herbicides and heavy metals –

Savvy Hospitality Buyers Turn to the Internet to Save Up to 50% on Custom Lampshades Savvy Hospitality Buyers Turn to the Internet to Save Up to 50% on Custom Lampshades Buying online direct from a quality domestic resource can beat overseas costs, speed delivery, and eliminate the middleman When hotel, motel, and resort buyers coordinate interior decor it can require purchasing hundreds of lampshades for rooms, lobbies, dining rooms and common areas as well as event and business facilities. This often involves customizing the lampshades in size, shape, or color to match aesthetics, whether for remodels, grand openings, or replacing any that become damaged or soiled throughout the year. Now to save up to 50% on custom lampshades, instead of ordering from overseas manufacturers or distributors, a growing number of astute hospitality buyers are finding a better alternative: purchasing direct from a quality domestic resource online. This is cutting out the middleman, beating overseas costs, and speeding delivery by months. To ensure the order is ready when needed, hospitality buyers are doing their homework and opting to work with an American company large enough to quickly produce hundreds of custom lampshades in time to replace needed stock or meet operational deadlines. “We needed custom lampshades tailored to our handmade lamps in time for our grand opening, and got them at a significant savings,” says Dennis Connolly, Director of Operations for Mahogany Bay Resort & Beach Club in Belize. The resort is part of Hilton’s global Curio Collection of distinctive four and five star hotels that offer travelers local discovery and authentic experiences. Until recently, hospitality buyers have typically ordered from a manufacturer in China and waited up to six months for delivery, which can interfere with operational deadlines. When dealing with overseas suppliers, questionable quality – along with long lead times to correct any mistakes – also makes this approach less desirable. “We could not wait for a container to arrive from East Asia,” says Connolly. “It would take too long and if there were any mistakes or quality issues, it would be even more problematic.” While ordering through an aggregator is an option, this entails paying a large middleman markup, which can double the wholesale cost. Even when aggregators hold ample inventory, it does not always meet hotel or motel requirements. Custom On Demand When Mahogany Bay Resort & Beach Club was preparing for its grand opening, everything had to be flawless, even its custom lampshades matched to handmade lamps crafted from a local hardwood. “We wanted the shades to have a tropical, British colonial look, but with a contemporary feel as well so they had to be custom,” says Connolly. When Connolly purchased about 150 custom lampshades for the resort’s rooms, he turned to Jack of All Shades, an Alabama based resource for custom hardback lampshades for 30 years that specializes in online sales for the hospitality industry. The company offers a wide range of hardback lampshade options, which run the gamut in shape (round, square, oval, rectangle, drums, pendant, and half round or square); in size (from small chandelier type to 72” oversized); and in color (with a palette of over 130). It also offers a number of fabrics (linen, silk, burlap, weave, poly cotton, faux leather, leather laced or washable/easy to clean) as well as lampshade fitter types. “The website is very simple to use,” says Connolly. “You can design your lampshade on the website, get expert help by phone if desired, and order the quantities you need.” Connolly says the custom lampshades perfectly match the handmade lamps and arrived in time for the resort’s grand opening. “We were able to achieve the look we wanted with large, barrel-shaped shades along with a natural, sand colored, cotton fabric that not only met our color requirements but also would wear well,” says Connolly. To provide a contemporary feel as well, the shades also sport a special handmade “rolled edge” that eliminates the need for trim. Instead of traditional 1/2” trim, the fabric forms the finished edge of the shades for a clean look that is becoming a trend in venues aiming for a modern vibe. In order to ensure that the shades work properly with every lamp, the lampshade company also offers a complete range of fitting types. This includes: spider and washer with harp, the most common type of fitting for table and floor lampshades; uno, usually found on smaller U.S. table lamps; euro, a European style fitting used with smaller table lamps; and clip-on, often used with accent lamps and chandeliers or Edison bulbs. “In the future, we will probably order custom lampshades for public areas as well as our rooms,” concludes Connolly. “Our interior designer was very happy with how well the shades turned out.” For more info, call 866-231-JACK (5225); email customerservice@jackofallshades.com; visit www.jackofallshades.com; write to Jack of All Shades at 521 Baltimore Ave., Albertville, Alabama 35950.

Strategies for Outsourcing Contract Services for Assays Strategies for Outsourcing Contract Services for Assays Commercialization of new diagnostic tests often requires a contract manufacturer that can fill in the gaps in development as well as regulatory assistance By Taryn Reynolds, Corgenix Inc. When new assays or diagnostic tests are ready for commercialization, there can be tremendous hurdles to overcome, including significant investment in the infrastructure for automated manufacturing and test equipment, hiring and retaining highly trained personnel as well as implementing high-end Quality Management Systems. In addition, FDA, ISO, GMP and other certifications may be required. Because smaller companies do not have the existing infrastructure, funds or desire to enter into assay manufacturing, many instead choose to outsource this critical function. Even large pharmaceutical companies sometimes choose to outsource manufacturing of smaller product lines that represent only a small part of the overall gross income. The simplest of these arrangements involve outsourcing the manufacturing of an existing, established test that is already being manufactured. In many cases, this can occur when a company wants to downsize or shutter manufacturing operations altogether due to cost overruns. Still others have invested in developing the test and acquiring the required PMA or 510K approvals, but decide instead to keep focus on development of the next new test instead of entering the world of manufacturing. In this way, they can remain a lean organization with a limited staff and avoid large capital expenses. However, the reality is that most opportunities in contract manufacturing do not fit neatly into a box. Instead, many assays arrive as “not-ready-for-prime-time” products that may not be fully developed, are still in the concept phase or proven in an R&D lab but not viable for scaled-up production. When this occurs, contract manufacturers are often called on to provide assay development assistance. This can take many forms including making changes to format (i.e. IT to lateral flow), identifying alternative reagents/antibodies and changing the coatings applied to microtiter wells. In addition, regulatory assistance is also a factor in most contract manufacturing situations. This includes receiving advice and guidance on how to meet the regulatory requirements of the FDA, but also achieve the required registrations required in other countries such as CE markings, Health Canada, and others. Therefore, finding a qualified contract manufacturer that can also provide development and regulatory assistance is often a critical, even strategic, decision. “Some of these new assays coming out of these labs are great products that are going to change the world, but the scientists that develop them have little understanding or background on the regulatory side, the quality side or how to manufacture it on a large scale,” says Stephen Hall, CFO of BG Medicine. In addition to having worked for a contract manufacturer earlier in his career, Hall now works for BG Medicine, a company that licenses the Galectin-3® Test. The in vitro diagnostic device quantitatively measures galectin-3 in serum or plasma by enzyme linked immunosorbent assay (ELISA) on a microtiter plate platform. The results of the test are used to aid in identifying patients with chronic heart failure that are clinically stable but at a higher risk of hospitalization and mortality. Hall says that when evaluating a contract manufacturer, he has a list of requirements that include ISO certification and a facility that is GMP and FDA-approved. In addition, he prefers to work with contract manufacturers with experience producing similar tests and formats. Ideally, the company would also have all of the necessary instrumentation in-house to conduct any steps of the manufacturing process. To do this, facilities often require space for devoted to IVD diagnostic test-related activities along with laboratory and a controlled environment production area. Ideally, the contract manufacturer is capable of preparing and producing materials in both a manual and automated production format, to accommodate the size and complexity of the product. The production area often houses state-of-the-art technologies including fully-automated filling and packaging lines along with large lot lyophilization capabilities. Other projects performed in the production area include component and raw material testing and qualification, general reagent formulation and preparation, assay and component production, final product assembly and final product testing. Leading contract manufacturers can even offer fulfillment and distribution services for completed test kits. This can include warehousing of products in a continuously-monitored, controlled, refrigerated storage area; order processing; domestic and international shipping; documentation assistance for shipping to new international destinations; coordination with freight-forwarders to optimize shipping costs; transportation stress testing; and shipping according to specific temperature specifications: blue ice, frozen, or room-temperature. Finally, physical security is also a concern. Contract manufacturing facilities must ensure the protection of all fixed assets and production areas with an advanced security system with access control, video monitoring and even critical condition monitoring for equipment to ensure redundant back-up in the event of a primary system malfunction. Data security with redundant replication is also important to ensure maximum data protection for software and critical data. In May 2007, Hall says BG Medicine entered into a biomarker product license and collaboration agreement with ACS Biomarker B.V. (Netherlands). After licensing the intellectual property, the company decided to pursue 510K clearance from the FDA and did initial work with a Netherlands based developer of IVD immunoassays. In 2009 the company engaged with a contract manufacturer to assist in final development and commercialization of the test kit. “When you don’t know if you have the volume to justify producing the test yourself, it just makes sense for a small company to use a contract manufacturer,” says Hall. According to Hall, the first step in working with the contract manufacturer involved a technology transfer, followed by optimizations and validations to determine compatibility with their manufacturing equipment and QC processes. Although the assay was already developed, not all the test methods for manufacturing purposes had been developed. The contract manufacturer had to develop the processes and the validations to create the gold standard tests to complete its in-process QC. In addition, some of the raw materials required validation to ensure availability and real-time stability to scale up for manufacturing. Because the assay

Municipalities Save Lives with Truck Side Guards Municipalities Save Lives with Truck Side Guards Lightweight safety barriers retrofit onto trucks to help prevent rear wheel crush hazard to cyclists and pedestrians In crowded city streets, one of the most deadly accidents to occur is a side impact collision between cyclists or pedestrians and municipal work trucks, including sanitation vehicles. “During a crash with a truck that has high ground clearance, vulnerable road users can fall into the exposed space between the front and rear wheels and suffer fatal crushing injuries,” states the U.S. Department of Transportation’s Volpe Center. “Nearly half of bicyclists and more than one-quarter of pedestrians killed by a large truck first impact the side of a truck.” Fortunately, there is a solution that is already saving lives. By installing truck side guards that physically block pedestrians and cyclists from being swept underneath the vehicle’s rear wheels, municipalities and even private fleets are protecting citizens, reducing liability and even potentially reducing insurance costs. Already mandated in certain metro areas in the U.S., these safety barriers made from aluminum or steel can be retrofitted onto existing trucks or incorporated into new vehicle fleets easily. This approach has already proven to be surprisingly effective in reducing fatalities. According to Volpe, following a national side guard mandate in the United Kingdom, cyclist fatalities fell 61% and pedestrian fatalities by 20% in side impact collisions with trucks. Side guards have been required since the 1980s in the European Union and Japan, and more recently in China, Brazil, and Peru. “Side guards protect bicyclists and pedestrians against falling under a moving truck and being run over,” says David Biderman, Executive Director and CEO of Solid Waste Association of North America (SWANA), the largest member-based solid waste association in North America. “Hauling companies and municipal sanitation departments that operate in congested cities should seriously consider adding them.” Although there is no federal mandate in the U.S. yet, Volpe has set national standards as a growing number of proactive municipalities such as Boston, Orlando, Seattle, San Francisco, New York City, and Washington, D.C. utilize truck side guards. Volpe’s recommended truck side guard standard (DOT-VNTSC-OSTR-16-05) states that Class 3 or above vehicles with a gross vehicle weight rating of 10,000 pounds or more should have underride protection. The standard includes dimensional and strength specifications for the side guards, including the ability to withstand 440 pounds of force. Reducing Risk Large trucks and buses have more difficulty making turns and seeing blind spots than smaller vehicles, due to their size, length, and driver elevation above street level. This can increase the risk of collision in populated urban areas, which can have not only cyclists sharing the road but also heavy foot traffic at corners and intersections. “Commercial trucks of all kinds need more room to turn right because right rear wheels often turn tighter than the front wheels, which is an added risk,” says Biderman. “Side guards can offer important protection against tight right turns if a cyclist or pedestrian is in the mirror’s blind spot on the truck’s right side.” Biderman added that another danger occurs as pedestrians become increasingly distracted, often texting, using smartphones, or listening to music via earbuds. This can make them less aware of their surroundings and more prone to have an accident. “Adding side guards can also be an effective way of preventing distracted pedestrians from getting seriously injured or worse if they step into the path of a moving truck,” says Biderman. One of the nation’s highest profile uses of truck side guards so far occurs in New York City, which is requiring the safety barrier on 10,000 vehicles by 2024 as part of its Vision Zero Action Plan for ending traffic deaths and injuries. To comply with New York City’s Vision Zero program and Volpe, Action Carting Environmental Services, a provider of non-hazardous waste management services for New York City and New Jersey, chose to retrofit its fleet of trucks with side guards. “We have retrofitted about 60 trucks with side guards from Dur-A-Guard, which is Vision Zero and Volpe compliant,” says Ken Levine, former Corporate Safety Director at Action Carting. “Using side guards is one of the most cost effective ways of reducing crash severity with cyclists, motorcyclists, and pedestrians on busy city streets. It is an inexpensive way to avoid a potentially catastrophic situation.” According to Levine, Dur-A-Guard, a Union, NJ-based manufacturer of truck side guards, worked with him to accommodate the various makes, models, and configurations of his fleet. “They custom fit the side guards with all of our trucks, even those with tanks, toolboxes, sidewalls, and bodywork,” says Levine. Such side guards do not need to be permanently welded onto trucks. To ease installation and maintenance, some companies like Dur-A-Guard offer side guards that lift up or swing down on hinges to offer access beneath the truck. Another high-density, aluminum design is lightweight enough to be removed by one person. “We looked into the swing up, swing down type side guards, which could help provide access under the truck, but liked the removable ones better,” says Levine. “One person can easily pull off the removable guards for maintenance and then put them back on.” According to SWANA’s Biderman, while it makes sense to have some uniformity to the side guards, the problem is there are many truck chassis used in the solid waste industry. “Even one company with ten trucks will have very different makes and models so it becomes challenging to provide a single sized side guard that works across an entire company’s fleet,” says Biderman. Since Dur-A-Guard has adapted the safety barriers to a full range of vehicle variations, however, the company created a universal design that accommodates most trucks, which can be shipped nationally. “Anyone involved with truck safety should look into side guards,” says Levine. “Those with a universal design would be helpful to cities or municipalities, which could get them drop-shipped and have their maintenance department install them.” Levine

Homeowners Reduce Heating/Cooling Bills Up to 30% by Adding Inner Insulating Windows Homeowners Reduce Heating/Cooling Bills Up to 30% by Adding Inner Insulating Windows An innovative approach enhances insulation and stops air infiltration without replacing existing windows For homeowners, insufficiently insulated windows can be a serious problem that breaks the family budget and sends precious dollars “out the window” in the form of excessive heating and cooling bills. When it is warm inside the home and cold outside, window panes will transfer heat by thermal conduction so additional heating is required to keep everyone comfortable, and a similar process is involved when it is hot outside and cool inside. Air leakage through window seals that crack over time worsens the problem, particularly in harsh weather. While single pane windows transfer the most heating and cooling, even dual pane windows may be insufficient to tame high utility costs. Now homeowners are looking to an innovative approach that adds an inner insulating window to existing windows. This can reduce heat loss by 77% or more for single paned windows, and heating/cooling bills by up to 30%, while stopping air infiltration for further energy savings and greater comfort. Adding the inner window, in fact, provides an additional layer of insulation with better insulation values than the best double pane windows. The same practice will also substantially reduce unwanted external street noise to provide homeowners a better night’s sleep and a more peaceful environment. Cutting Heating and Cooling Cost Two factors are vital to keeping home heating and cooling costs from escalating: the window’s basic insulation value and preventing air infiltration through and around the window’s seals. Window Insulation Value The home window’s basic insulation value is largely a factor of the air pockets or bubbles that adhere to panes of glass. These serve as insulative barriers to the transfer of heating or cooling by thermal conduction. “Air pockets or bubbles ‘adhere’ to glass, which is the major reason glass has any insulating value,” explains Randy Brown, President of Soundproof Windows, a national manufacturer of window energy efficiency and soundproofing products. “The more such air bubbles adhere to the glass, the better the insulation.” In practice, with a single pane of glass there are two air bubbles, one on each side of the pane. With dual pane units, there are three bubbles, one on each side of the panes and one between them. However, according to Brown, with a second window acting as an insulating window, there are actually five bubbles when used with a single pane window if the air space is more than 1 inch. As an example, an air space of 2-4 inches usually separates the existing window and the Soundproof Window, which serves as a “second insulative window” that can be installed easily in front of the existing window. The product is designed specifically to match and function like the original window, no matter its design or whether it opens or closes. In terms of measuring energy efficiency, the R value of a window indicates its resistance to transferring heat. Better windows have higher R values. Adding such a “second window” can actually increase the home window’s insulation R value by 2.5 or more, dramatically reducing heat loss. This reduces window heat loss by about 77% for single pane windows. It can substantially improve insulation values for dual pane windows as well. A window with a single pane of glass, for instance, has an R value of 1.15. One with a dual pane of glass, with ½” air space, has an R value of 1.81. However, an existing single pane window with a “second insulative window” would have an R value of 3.84; and a double pane window, an R value of 4.40. Preventing Air Infiltration Air infiltration due to leaky window seals often lets in hot or cold air, depending on the season, which can cause uncomfortable temperature differences within the home. To compensate, homeowners or family members often crank up the air conditioning or the heat, which runs up the family utility bill. Due to wind and temperature cycling, particularly in extreme climates, most home window seals typically start leaking significantly within a few years. To prevent such air infiltration, however, Soundproof Windows frame seals are held under a constant tension, using custom made tempered stainless steel springs that actively squeeze down on the window. This means the window seal is flexible, constant and always working. When used in combination with existing windows, in fact, the second window seals effectively eliminate any hot or cold outside air from leaking into the home from this source. This significantly reduces the need to crank up air conditioning or heating to maintain comfort, which further increases home energy savings. In terms of reliability, such seals are guaranteed for a 50 year lifespan. “The Soundproof Windows have helped to prevent cold drafts from entering even when it’s windy outside, which makes our home more comfortable,” says Doug Alexander, a condo owner along with his wife in White Rock, BC, Canada. “The added insulation and better seals also improve energy efficiency.” Silencing External Noise The same approach of adding an inner second window can also do double duty for homes by preventing loud external noise sources, such as traffic, honking, leaf blowers, or noisy neighbors from penetrating the windows to disturb homeowners’ sleep or peace of mind. The inner window essentially reduces noise from entering on three fronts: the type of materials used to make the pane, the ideal air space between original window and insert, and improved, long-lasting seals. The combination can reduce external noise by up to 95%. “The first noise barrier is laminated glass, which dampens sound vibration much like a finger on a wine glass stops it from ringing when struck,” explains Brown. “An inner PVB layer of plastic further dampens sound vibrations.” Air space of 2-4 inches between the existing window and the Soundproof Window also significantly improves noise reduction because it isolates the window frame from external sound vibrations. The company’s spring-loaded seals in

Strategies for Outsourcing Contract Services for Assays Strategies for Outsourcing Contract Services for Assays Commercialization of new diagnostic tests often requires a contract manufacturer that can fill in the gaps in development as well as regulatory assistance By Taryn Reynolds, Corgenix Inc. When new assays or diagnostic tests are ready for commercialization, there can be tremendous hurdles to overcome, including significant investment in the infrastructure for automated manufacturing and test equipment, hiring and retaining highly trained personnel as well as implementing high-end Quality Management Systems. In addition, FDA, ISO, GMP and other certifications may be required. Because smaller companies do not have the existing infrastructure, funds or desire to enter into assay manufacturing, many instead choose to outsource this critical function. Even large pharmaceutical companies sometimes choose to outsource manufacturing of smaller product lines that represent only a small part of the overall gross income. The simplest of these arrangements involve outsourcing the manufacturing of an existing, established test that is already being manufactured. In many cases, this can occur when a company wants to downsize or shutter manufacturing operations altogether due to cost overruns. Still others have invested in developing the test and acquiring the required PMA or 510K approvals, but decide instead to keep focus on development of the next new test instead of entering the world of manufacturing. In this way, they can remain a lean organization with a limited staff and avoid large capital expenses. However, the reality is that most opportunities in contract manufacturing do not fit neatly into a box. Instead, many assays arrive as “not-ready-for-prime-time” products that may not be fully developed, are still in the concept phase or proven in an R&D lab but not viable for scaled-up production. When this occurs, contract manufacturers are often called on to provide assay development assistance. This can take many forms including making changes to format (i.e. IT to lateral flow), identifying alternative reagents/antibodies and changing the coatings applied to microtiter wells. In addition, regulatory assistance is also a factor in most contract manufacturing situations. This includes receiving advice and guidance on how to meet the regulatory requirements of the FDA, but also achieve the required registrations required in other countries such as CE markings, Health Canada, and others. Therefore, finding a qualified contract manufacturer that can also provide development and regulatory assistance is often a critical, even strategic, decision. “Some of these new assays coming out of these labs are great products that are going to change the world, but the scientists that develop them have little understanding or background on the regulatory side, the quality side or how to manufacture it on a large scale,” says Stephen Hall, CFO of BG Medicine. In addition to having worked for a contract manufacturer earlier in his career, Hall now works for BG Medicine, a company that licenses the Galectin-3® Test. The in vitro diagnostic device quantitatively measures galectin-3 in serum or plasma by enzyme linked immunosorbent assay (ELISA) on a microtiter plate platform. The results of the test are used to aid in identifying patients with chronic heart failure that are clinically stable but at a higher risk of hospitalization and mortality. Hall says that when evaluating a contract manufacturer, he has a list of requirements that include ISO certification and a facility that is GMP and FDA-approved. In addition, he prefers to work with contract manufacturers with experience producing similar tests and formats. Ideally, the company would also have all of the necessary instrumentation in-house to conduct any steps of the manufacturing process. To do this, facilities often require space for devoted to IVD diagnostic test-related activities along with laboratory and a controlled environment production area. Ideally, the contract manufacturer is capable of preparing and producing materials in both a manual and automated production format, to accommodate the size and complexity of the product. The production area often houses state-of-the-art technologies including fully-automated filling and packaging lines along with large lot lyophilization capabilities. Other projects performed in the production area include component and raw material testing and qualification, general reagent formulation and preparation, assay and component production, final product assembly and final product testing. Leading contract manufacturers can even offer fulfillment and distribution services for completed test kits. This can include warehousing of products in a continuously-monitored, controlled, refrigerated storage area; order processing; domestic and international shipping; documentation assistance for shipping to new international destinations; coordination with freight-forwarders to optimize shipping costs; transportation stress testing; and shipping according to specific temperature specifications: blue ice, frozen, or room-temperature. Finally, physical security is also a concern. Contract manufacturing facilities must ensure the protection of all fixed assets and production areas with an advanced security system with access control, video monitoring and even critical condition monitoring for equipment to ensure redundant back-up in the event of a primary system malfunction. Data security with redundant replication is also important to ensure maximum data protection for software and critical data. In May 2007, Hall says BG Medicine entered into a biomarker product license and collaboration agreement with ACS Biomarker B.V. (Netherlands). After licensing the intellectual property, the company decided to pursue 510K clearance from the FDA and did initial work with a Netherlands based developer of IVD immunoassays. In 2009 the company engaged with a contract manufacturer to assist in final development and commercialization of the test kit. “When you don’t know if you have the volume to justify producing the test yourself, it just makes sense for a small company to use a contract manufacturer,” says Hall. According to Hall, the first step in working with the contract manufacturer involved a technology transfer, followed by optimizations and validations to determine compatibility with their manufacturing equipment and QC processes. Although the assay was already developed, not all the test methods for manufacturing purposes had been developed. The contract manufacturer had to develop the processes and the validations to create the gold standard tests to complete its in-process QC. In addition, some of the raw materials required validation to ensure availability and real-time stability to scale up for manufacturing. Because the assay was

CNC Equipment Suppliers Turn to High Torque Retention Knobs to Ensure Customer Satisfaction CNC Equipment Suppliers Turn to High Torque Retention Knobs to Ensure Customer Satisfaction Suppliers of CNC machining centers, toolholders and tools are increasingly urging customers to add High Torque retention knobs to ensure their products are not incorrectly assigned blame for vibration and chatter issues CNC horizontal and vertical machine, tool and toolholder manufacturers and distributors spend years establishing strong relationships with customers by providing top-quality, precision equipment. Sadly, these relationships can easily be undone by a small, less than $30 part: the retention knob – an overlooked, yet critical component in the machining process. In fact, the problem is so prevalent in CNC equipment that utilizes drawbars to hold tapered toolholders securely in the spindle that many are adopting a policy of only selling the High Torque retention knob; or at minimum, strongly urging customers to invest a few dollars more for an item they do not even sell. After all, many suppliers have already discovered a hard truth: when machinists experience vibration, chatter and fretting after purchasing equipment, they tend to blame the new spindle, toolholder or high-end carbide cutting tool. This, despite the fact that improper seating of the toolholder due to poorly designed traditional retention knobs is more likely the cause. When this occurs, it reflects poorly on the supplier and can cost them considerable business both short-term and in repeat business. According to Craig Gilsinger, Applications/Quality Manager for JTEKT Toyoda Americas for more than 20 years, this real-world scenario is the reason the company regularly recommends High Torque retention knobs for use on its vertical and horizontal machining centers. “If the cutting conditions are poor, the customer immediately assigns blame to the machine,” explains Gilsinger. “So, we regularly recommend [the High Torque retention knob] to customers. It not only ensures the equipment will cut better, but also that it won’t get blamed for machining issues when it is not the cause.” More often than not, says Gilsinger, investigations of vibration and chatter issues point to improper seating of the toolholder in the spindle. That is because when a standard retention knob is tightened, it can produce a bulge in the taper that prevents full contact and correct seating in the spindle. As a result, the toolholder is unable to pull completely into the spindle and, subsequently, cannot make contact with up to 70% of its surface. “We have seen many situations where retention knobs have been overtightened,” explains Gilsinger. “A guy goes to the workbench and uses a wrench and a hammer to tighten the retention knob, and it is certainly not to the proper torque with this method. This ends up distorting the taper and so the tool does not seat in the taper correctly.” This can cause a multitude of problems, which too often get blamed on the suppliers’ equipment: vibration and chatter, poor tolerances, non- repeatability, poor finishes, shortened tool life, excessive spindle wear and tear, run-out, and shallow depths of cuts. Surprisingly, this known design flaw, with its far-reaching consequences, is often overlooked or even dismissed. So when JTEKT Toyoda Americas learned about the High Torque retention knob offered by JM Performance Products, Inc. (JMPP), the company quickly decided to recommend it with each machining center purchase as well as on its full turnkey systems. The High Torque retention knob is designed with a longer reach so that it threads deeper into the threaded bore of the toolholder. Consequently, all thread engagement happens in an area of the toolholder where there is a denser cross-section of material to counter deformation. It also features a precision pilot, and is balanced by design, to increase rigidity. What is more, to guard against the High Torque retention knob being over-tightened, which can still produce a bulge, the company provides specifically calculated torque specs based on drawbar pressure. By combining the High Torque retention knob with the proper torque, spindle contact with the taper is improved to close to 100% every time, which drastically reduces vibration and chatter. High Torque retention knobs work with all existing toolholders including BT, DIN, ISO, and CAT toolholders from 30 taper to 60 taper. For Dan Carlstrom of Carlstrom Associates, a manufacturer’s rep organization that sells toolholders, milling products and workholding systems, the “light bulb” moment came when he recommended the High Torque retention knob to a customer that was struggling with a boring product he had sold them. “The customer was having a problem holding size on a component, so they had to take multiple boring passes and then do a final reaming pass to get this hole to size,” explains Carlstrom. “When they put the High Torque retention knob on the toolholder, the boring tool was able to cut the hole to size, in tolerance, in one pass.” “They never gave me total cost savings, but needless to say it was significant. It also solved a huge headache for them,” adds Carlstrom. Carlstrom, who emphasizes that his company does not represent or sell JMPP’s High Torque retention knobs, says whenever he runs a test of his product for a customer he does so with the knob installed to eliminate poor seating in the spindle as a variable that could affect performance. “When I run an end mill test, a toolholder test, or a boring bar test, I will not run it without the High Torque retention knob, period,” says Carlstrom. “I know it will make my tools, which I get paid for, run properly.” By recommending or supplying High Torque retention knobs, suppliers can also earn the respect and gratitude of their customers, which can result in increased loyalty and referrals, all of which provides them with a competitive edge. For more detailed information contact JM Performance Products, Inc., 1234 High Street, Fairport Harbor, OH, 44077; visit www.jmperformanceproducts.com; call (440) 357-1234; email sales@jmppinc.com

Making the Case for the ROI of Plasma Treatment Equipment Making the Case for the ROI of Plasma Treatment Equipment Despite its effectiveness, plasma treatments for surface modification and chemical deposition remain less than fully understood. So, too, are the tool selection choices. For this, vendors work with customers to select equipment and help justify the ROI Plasma treatments are a powerful technique for solving challenging surface issues whether through precision cleaning or by increasing surface wettability to promote adhesion. Plasma can also be used to deposit a wide range of chemistries onto surfaces. So, when surface challenges arise and engineers and production personnel are tasked with evaluating plasma as a possible solution, it often involves a quick immersion into the physics and chemistry behind the technology. But it also extends to how plasma is applied to each part, the type and size of chamber, tooling options, and facility requirements. Because any investment in technology must be justified based on ROI, factors such as budget, throughput and maintenance costs, must be considered prior to equipment purchase. Therefore, whether looking to purchase equipment for full-scale manufacturing or for R & D, here are some of the key factors that should be considered when approaching an equipment vendor. Plasma Consideration With the right type and configuration of equipment, the collective properties of the plasma (ions, electrons and radicals) produced in the chamber can be controlled to alter the properties of surfaces without affecting the underlying materials. For example, surface etching can be achieved through pure chemical etching of the surfaces or through physical etching or through both chemical and physical etchings. In chemical etching, plasma activated gas species attack the material surfaces forming volatile derivatives of the materials that leave the surfaces. In physical etching, ions in the plasma are accelerated towards the substrate surfaces. On their way to the substrate surfaces they may collide with other neutral atoms/molecules to ionize them while the original ions may become neutrals. The ionized atoms/molecules start accelerating toward the substrates and the newly created neutrals continue heading toward the substrate surfaces by maintaining their pre collision velocities. As a result large number of ions and neutral species bombard the substrate surfaces causing substrate materials to eject from the surfaces. In fact, there are so many combinations and potential chemistries involved, that equipment vendors such as PVA TePla in Corona, California often host customers to answer questions and assist in the selection of the right tool for their applications. Although there continues to be much to learn about the physics of plasma, lead scientist Dr. Michael Barden says that most customers are more focused on the results of the process and how the modified surfaces can be tested. Even more questions are targeted at the type of tool that should be purchased, the facility requirements and the overall costs. “Many customers don’t care how the plasma is generated, they care about the cost, throughput and the outcome,” says Barden. Equipment Selection Although there are atmospheric systems for inline manufacturing, the majority of plasma treatments are conducted in low pressure vacuum chambers. So, from an engineering perspective, Barden says it can be important to understand the basics of what occurs within the plasma chamber. Most low pressure plasma systems involve a chamber, vacuum pump, power supply, electrodes, the system interface and control, electrical components, gas/monomer distribution components, and exhaust system. In general, these components have multiple options to accommodate the various processes that will be performed in the chamber. In other words, if the vacuum chamber will be used for chemical deposition, surface functionalization, etching or cleaning, it likely will require a slightly different gas delivery system, power generator, temperature controls or chamber pressure. According to Barden, there are three primary cost drivers in any plasma system – the type and size of chamber, power generator and vacuum pump. The vacuum chamber is a rigid enclosure from which air and other gases are removed by a vacuum pump. The size of the chamber is dictated by the largest size of substrate that will be processed in the chamber. This volume requirement directly influences the size of vacuum pump required. Vacuum pumps come in wet and dry configurations. Wet pumps use low vapor pressure oil to seal in gas to create vacuum and also lubricate its components. Dry pumps do not use any oil to seal in gas, but they may or may not use oil to lubricate the components. The size and speed of the Pump have a direct impact on processing speed as well as actual process results that can be achieved. In addition a whole variety of factors including size of the chamber, the distance the pump is from the chamber, the length and diameter of the hose connecting the pump and the chamber, the base processing pressure required, time required to reach the base pressure, process pressure and gas load during processing. As for the power generator, the type and size of substrate is a determining factor. If it is a conducting substrate, a dc or rf or mw power supply can be used. Non-conducting materials require an rf or mw power supply. There can be other important considerations as well. The temperature requirements for the processes conducted in the chamber will determine the required maximum substrate temperature for the system. Understanding the thermal budget of the substrates may require adding a temperature controller/chiller to the system. Another key factor is whether the tool will be used for production or R&D. If for production, will it be a fully automated or a semi-automated? For R&D, will it be a semi-automated or a manual? Facility Considerations For production engineers, the facility considerations such as the footprint of the system, types of connections required and accessibility for maintenance are equally important. So, too, are the ongoing consumable costs for electricity, gas, compressed air, reagents and chemicals involved. The production volumes factor heavily in this consideration as the cost-per-piece for 100,000 parts is very different than production of 8 million parts. “The duty cycle

Physical Therapy Patients Benefit from In-House Diagnostics Physical Therapy Patients Benefit from In-House Diagnostics For patients that seek treatment from physical therapists, the prospect of achieving faster and better results when rehabbing from injury or receiving treatment for pain is a no-brainer. Now, with an increasing number of physical therapy clinics incorporating in-house diagnostics into the practice this is not only possible, but expected. Armed with more objective results from established tests that include nerve conduction, musculoskeletal ultrasound and other tests, physical therapists are now able to troubleshoot issues with challenging patients much more quickly and accurately in the clinic. As a result, patients are able to get back to work sooner, return to their beloved sports/exercises and even potentially lead a more pain-free existence without medication. The traditional approach to PT In the traditional approach, physical therapists evaluate patients through a physical examination to determine the ideal treatment plan. However, Physical Therapy physical evaluation tests may miss pathologies and lead to ineffective treatment. “As physical therapists, a lot of what we do is relatively subjective testing,” explains Nathan Shields, co-owner of Rise Rehabilitation Specialists with 18 years as an orthopedic physical therapist. “Many of the tests are scientifically proven, but are still based upon the skill level and experience of the therapist.” In the past, when more sophisticated diagnostic tests were required the patient was typically referred to a small universe of specialists in a process that could take several weeks to receive the results. Now, however, PTs are regularly bringing this type of testing into the clinic. This not only requires a significant investment in the equipment, but also training to accurately conduct the tests. Fortunately, this is being facilitated by national franchise organizations such as Hands-On Diagnostics that help physical therapy practices establish in-house diagnostic services. To date, the franchise has expanded to 18 different states with over 115 physical therapy facilities. Among the tests that physical therapists can be trained on include electromyography (EMG), Nerve Conduction Studies (NCS), musculoskeletal and neuro ultrasound, vestibular testing to evaluate patients with vertigo and balance problems and Evoked Potential tests. EMG/NCS testing is one of the most reliable diagnostic tools for many dysfunctions of the Neuromuscular System. An EMG measures the electrical activity of muscles at rest and during contraction. Nerve Conduction Studies (NCS) measure the health of the nerves. Physical therapists have been able to perform EMG and nerve conduction tests for more than 45 years. In 1978, the American Physical Therapy Association established a specialty program through the American Board of Physical Therapist Specialties for certification in clinical electrophysiology. The other diagnostic technique is Musculoskeletal Ultrasound (MSKUS) imaging, which uses sound waves to produce pictures of muscles, tendons, ligaments and joints throughout the body. It is used to help diagnose sprains, strains, tears, and other soft tissue conditions and to guide therapeutic procedures. In addition to identifying the severity of the problem, EMG and MSKUS can be used to locate the actual source of pain conditions as well as to monitor ongoing improvement over the course of the physical therapy treatment plan. Patient Feedback According to a September 27, 2017 article in Musculoskeletal Care, “Physiotherapists utilizing diagnostic ultrasound in shoulder clinics. How useful do patients find immediate feedback from the scan as part of the management of their problem?” the utilization of diagnostic ultrasound by physical therapists in patients with shoulder problems concluded that patients highly rated the information gained from ultrasound imaging in a physical therapy environment and felt it assisted them in the understanding, reassurance and management of their problem. According to the article, to arrive at this conclusion a questionnaire was offered to 103 patients that underwent ultrasound imaging as part of a shoulder assessment over a 6-month period. According to the article, “Regarding the ability to understand their shoulder problem better and in feeling reassured about their problem, 97% of patients either strongly agreed or agreed that this was the case. Concerning the capability of managing their problem, 89% of patients strongly agreed or agreed that they felt more able to do this. In total, 96% of patients evaluated the ultrasound scan to be of very high/high value to them.” For Physical Therapist Nathan Shields, perhaps the most important aspect is that patients are experiencing better, faster results. “We are now able to treat patients with more certainty and, in some cases, we have been able to use the testing to create protocols and get immediate responses on the physical therapy side,” says Shields. For more information, contact Hands-On Diagnostics at (888) 447-6014 or visit www.diagnosticsforpt.com

Simplifying Moisture Measurement to Improve Quality of Powders and Bulk Solids Simplifying Moisture Measurement to Improve Quality of Powders and Bulk Solids Instantaneous, “point-and-measure” handheld analyzers that can be operated by virtually any technician deliver lab-quality moisture readings in seconds In industries that produce powders and bulk solids, controlling moisture content can impact the purchase price, shipping costs, material handling and, perhaps most importantly, the quality of the final product. When processing dry bulk solids such as food ingredients, chemicals, pharmaceuticals, pigments, minerals, etc. the amount of moisture in the product can have a wide range of effects. A product’s quality, as well as transactions based on weight, can be adversely affected by improper moisture contents. Furthermore, the satisfaction of legal requirements that are present in many industries is a determining factor influencing a company to measure moisture content. However, until recently conducting frequent moisture content tests throughout the process or in the field has been difficult. In many cases, the primary barrier has been the expertise and time required to conduct such tests. Often sophisticated moisture measurement devices must be operated by trained personnel that can properly calibrate the equipment. Many also require meticulous sample preparation and disposal. Fortunately, handheld devices are now available that allow even less-skilled personnel to take lab-quality moisture measurements. These “point-and-measure” options allow moisture readings to be quickly taken at any stage of the process, as well as at loading docks, on trucks, at suppliers, or in bins, vats or vessels. By simplifying the process, powder and bulk solid producers can increase the quality of their products from raw material receipt and formulation to end product manufacturing and distribution. The Many Benefits of Moisture Readings Although the reasons for measuring the moisture content of powders and bulk solids can vary, the primary motivation is to improve product quality and the bottom line. Monitoring moisture content in all stages of production ensures the most efficient processing. From measurement of incoming materials to mid‐process measurement, the optimization of plant resources and product quality will be ensured. A prime example is extending the shelf-life of powders in particular food ingredients. When moisture content is too high, mold can develop; when it’s too low, the product can become stale and the taste altered from ideal. Establishing the moisture content is also very important when mixing two substances together. If the mixing is not done at the proper moisture levels, the way the two products react can be affected. This includes any chemical reactions that might take place, the way the two are blended together, or the amount one substance is dissolved into another. It is also important to know the precise moisture content in any raw materials prior to beginning the manufacturing process. Otherwise, the product’s time in the dryer, the dryer temperature, the conveyor belt speed, and many other factors must be modified each time a new shipment of the product is introduced. Another benefit of frequent moisture measurement is for products sold based on regulated moisture content. Prescribed percentages must be met in order to comply with these specifications. In certain industries, heavy fines could be levied, while in others, the product or substance will not be accepted by the regulating agency. These industries include gypsum and pharmaceutical manufacturers, among others. There may even be legal ramifications, if the acceptable moisture content of a product is decided prior to purchase or shipping. Fees can be levied on companies that do not ship at the agreed moisture level or the product could be rejected outright. Finally, since moisture content contributes significantly to the weight of such materials, properly drying a substance to acceptable limits before it is transported can dramatically reduce shipping and disposal costs. Simplifying Moisture Measurement Although traditional laboratory and online based moisture measurement techniques are useful in the right settings, they have lacked the simplicity and flexibility required for frequent spot checks. One common test is Loss on Drying, which measures the total material weight change after drying. However, such tests typically require a sample to be prepared and brought back to the lab. The test takes at least 15 minutes to several hours to perform, which is too slow when more immediate measurements are required. It also requires the sample to be altered or destroyed. As a result, secondary test methods have typically been used to deliver faster results. This type of test uses an indirect method and a single conversion to achieve accurate results. Secondary measurement techniques are routinely accepted as equal to the gold standard method. Examples are speedometers, common infrared and liquid thermometers and most pressure gauges. If there is a disadvantage, it is that the instrument must first be calibrated to ensure accurate results. In some cases, calibration could only be performed by trained staff familiar with the equipment. In response, industry innovators have developed a simplified approach that allows even less-trained personnel to take portable, instant moisture readings of powdered bulk product as needed. The approach involves moisture meters that utilize Near-Infrared (NIR) light, a highly accurate, non-contact secondary measurement method that can deliver immediate, laboratory quality moisture readings. “NIR moisture meters allow very accurate instant measurement of solids and liquids without contact or sample preparation, so there is no contamination in handheld and online models,” says John Bogart, Managing Director of Kett US, a manufacturer of a full range of moisture and organic composition analyzers. “Once the meter has been calibrated against the lab or production standard, the calibration is stored in the device so no calibration is required in the field. Measurements are fully traceable to the original measurement method.” In addition, because the process is non-destructive, samples remain unaltered so they can be used for additional tests or put back into the product stream. “NIR moisture meters follow the principle that water absorbs certain wavelengths of light,” says Bogart. “The meter reflects light off the sample, measures how much light has been absorbed, and the result is automatically converted into a moisture content reading.”

Reducing Parts Costs as Production Scales Up Reducing Parts Costs as Production Scales Up OEMs turn to one-stop metal parts shops that can transition to more cost-effective fabrication and machining techniques as demand increases When OEMs outsource component parts manufacturing, the type of fabrication, stamping or machining technique utilized is often a major factor in the final, per-piece cost. However, the initial volumes required may also dictate the metalworking technique or process selected, particularly for new products just beginning to find a market. While certain complex metal parts can only be machined, thinner gauge parts and enclosures are typically stamped using hard tooling or fabricated using lasers, turret presses or press brakes. For start-ups or smaller companies with more modest production requirements, however, avoiding the high, upfront costs of hard tooling can be appealing. As a result, fabrication alternatives that do not require that investment – even if the cost per piece is higher – are the better initial choice. But what happens when demand increases and an OEM needs to scale up production? When this is the case, determining the ideal time to transition to a more economical alternative can be challenging. In some cases, it can even involve the difficult decision to move from a trusted supplier. After all, most sheet metal fabricators do not also offer stamping, and vice versa. This is where more sophisticated “one-stop” metal parts manufacturers can deliver a significant advantage. By offering the full gamut of sheet metal fabrication, stamping and machining options under one roof, these larger operations are in a much better position to scale with the customer as demand increases. This includes facilitating the transition to hard tooling, mixing and matching metalworking techniques for multi-component assemblies, and incorporating hybrid and secondary tooling approaches to further reduce costs. The Progression of Options According to Bob Denholtz, president of DureX Inc., deciding on the best technique to manufacture a part involves a careful analysis of the production volume versus the cost of the hard tooling. “With a sheet metal part that costs $10, it may cost $6 for stamping, but the OEM may have to spend $30-40,000 in tooling. So for that $4 saving, they need to make sure they have 10-20,000 pieces so they can pay off the tooling quickly,” says Denholtz. Founded in 1946, DureX, Inc. operates a 120,000 square foot facility that provides metal stamping, sheet metal fabrication and CNC machining. The company has more than 50 presses with capacity up to 400 tons, along with laser cutting equipment and turret presses – in addition to value-added services such as powder coating, assembly, packaging and fulfillment. According to Denholtz, a one-stop-shop can work with a customer by offering a full progression of options based on what he calls “the ROI threshold.” For example, for a startup that needs 500 units per month, it may not make sense to spend the money for stamping, so the part can be fabricated. As the program matures and the OEM goes from 500 to 5,000 units per month, the customer can move from fabrication to hard tooling in a smooth transition with the same supplier. In one real-world example, Denholtz says a customer was spending $18 for a power supply chassis with a $4 cover. As volume requirements increased, DureX suggested it was time to move to hard tooling. This reduced the overall cost from $22 to $14. “The customer is saving $8 a unit and now they are up to over 3,000 units a month,” explains Denholtz. “The tooling cost $80,000, so at $24,000 in savings each month it took 3.5 months to get the money back.” Had it not been cost-effective to use hard tooling for the box, it many have been for the cover because it is a cheaper tool. In that case, the customer could continue to receive a set of parts from the same supplier. A hybrid approach can even be used. “I may fabricate a part on our turret press or use laser cutting and then use a hard tool to form it into a box,” says Denholtz. Tools can also be staged to create a blank, before a secondary press is used to form it into a box with another hard tool. Finally, if it is determined that it is worth the cost, a full-blown progressive die can be purchased that will form the entire box completely with very little labor. Air Conditioning Parts For Michael Milazzo, CEO of Simon-Aire, working with a metal parts supplier that actually initiates suggestions is highly unusual. “I’ve worked with many sheet metal fabricators over the years and they are often silent, says Milazzo. “They just keep moving forward without stopping to say, ‘listen, if you do this, you can save yourself 12 passes,’ or ‘the weight of the sheet metal is too heavy, if you use a lower gauge, you can reduce your costs.’“ Simon-Aire Inc. manufactures Packaged Terminal Air Conditioners, a type of self-contained HVAC system commonly found in hotels, senior housing facilities, hospitals, dormitories and apartment buildings. The company also offers parts and accessories, including replacement chassis, hydronic heat assemblies, louvers, wall sleeves, room enclosures and control components. For these products, Simon-Aire requires a variety of metal parts and components from DureX. “I’ll get a phone call saying ‘have you thought about this?’ says Milazzo. “That’s a good phone call to get. They don’t bill me for that – it doesn’t make them more money – it’s just part of the relationship.” “They are not just trying to get more money from me. They are trying to save us money while improving the product to keep us alive another day,” says Milazzo. There are other advantages to working with a parts manufacturer with experience across the metalworking spectrum. “I basically get to pick their brains on every little ‘what if’ that I’ve been considering,” say Milazzo. “They are able to pull from their experience with the customer that makes rifle components and the one that makes

LiFi Ready for its Moment in the Spotlight LiFi Ready for its Moment in the Spotlight Mainstream adoption of LiFi wireless optical data transmission is now possible with LED light bars that replace the most widely utilized light source in the word – fluorescent tubes The promise of LiFi (light fidelity), which utilizes the very LED lights that illuminate a work space to transmit more secure, high speed, wireless data at rates that can go well beyond those possible with Wi-Fi, has now advanced to the point of introducing a new form of mainstream implementation. This new development results from the introduction of the first LED “light bar” fixtures equipped with the required transmission technology and designed to replace the most ubiquitous form of lighting in commercial and industrial facilities: fluorescent tubes. With an estimated 3-4 billion installed fluorescent tubes throughout the world, the integration of built-in LiFi transmission technology in new and retrofit LED light bars is now moving LiFi beyond the pilot stage to full-scale implementation in offices, schools, warehouses and other facilities. “LiFi is not a concept, it is really here,” says Harald Haas, co-founder and Chief Science Officer of pureLiFi, a company that is spearheading the development of the technology. “If people want to engage, they can purchase the products right now.” What is LiFi? LiFi is a high-speed, secure, fully networked wireless communication technology similar to Wi-Fi. However, LiFi utilizes the entire light spectrum where Wi-Fi utilizes radio frequencies (RF). To do this, the LED light fixtures used in many energy-conscious homes and offices are outfitted with a module that controls the light for optical data transmission. The high speed light pulses are invisible to the naked eye, yet can be used to transmit data at extremely high speeds to a receiving device located in a laptop, computer tower, cell phone or other smart device. In the future, LiFi will be embedded into the mobile devices we use every day, as well as play a key role in machine-to-machine communication and the Internet of Things (IoT). The utilization of visible light provides a host of intriguing benefits that far outpace what is currently possible with the radio frequency waves used by Wi-Fi and cellular networks. When compared to the overloaded full RF spectrum, the light spectrum is 1,000 times larger and is currently unregulated with no licensing fees. In lab conditions the technology is already capable of 10 Gbps speeds, and with the available bandwidth potential, data transmission speeds up to 100 times faster will be possible in the near future as the technology advances. LED Lighting Manufacturers Push LiFi Forward According to Haas, who is considered the “father of LiFi” and has been working in the field for the past 15 years, the implementation of the technology into lighting fixtures has necessitated a close partnership with LED light manufacturers. “The lighting manufacturers are very important to move LiFi forward,” says Haas. “They know how to design lights and fixtures and we know what needs to be done to create high speed data networks out of light and add communication capability to it.” Until recently, most of these fixtures were small lamps or recessed can lights. Now, one of its partners, Linmore LED, is introducing the first LiFi enabled LED light bars designed to replace fluorescent tube lighting. For those that want to experience the technology in action, the company is demonstrating a complete, functional LiFi system using the new linear LED light bars at its facility in Fresno, Calif. With the technology, data speeds have been clocked at 43 Megabits-per-second (Mbps) up and down. “Linmore LED is the first company in the world to bring this technology not only into new light bar fixtures, but also be able to retrofit linear fluorescent fixtures that employ the LiFi technology,” says Haas. Linmore LED originally built its reputation in the retrofit market, utilizes its own proprietary designs involving optics, thermal dissipation and a number of other techniques to ensure its LED products perform in the top 1% in energy efficient in the industry. According to Paul Chamberlain, CEO of Linmore LED, the partnership with pureLiFi was a good fit due to the modular nature of the company’s LED light bars. The product’s design allowed for the integration of the LiFi modules in the ideal position on the light bar, without affecting critical aspects such as lighting distribution, thermal dissipation or overall performance. Retrofit fixtures, even those that are not LiFi enabled, are in great demand as many facilities seek to drive down energy costs by as much as 70-80% by converting to LED technology. This trend is also being driven by the increased operating life of LEDs and concerns about the toxic mercury utilized within fluorescent lamps that complicates disposal. This provides a very real scenario where building owners and facility managers can adopt LiFi technology while dramatically decreasing lighting-related energy costs at the same time. “Businesses want to leverage an LED upgrade and get more than just lighting, says Paul Chamberlain, CEO of Linmore LED. “Utilizing an existing part of a building’s infrastructure – lighting – opens up endless possibilities for many other technologies to have a deployment backbone.  Internet of Things (IoT), RFID, product and people movement systems, facility maintenance, and a host of other technologies are taken to the next level with LiFi available throughout a facility.” Security Benefits Among the expected early adopters of the technology are those that seek greater security of data transmission than is possible with Wi-Fi. For this reason, initial markets expected to adopt LiFi technology include federal government and defense, banking, financial institutions and hospitals. LiFi is a far more secure form of data transmission than Wi-Fi because a receiving device must be directly within the cone of light to receive a broadcasted signal. Visible light, including near-infrared wavelengths, cannot penetrate opaque objects such as walls, which means that the wireless signal is constrained to within a strictly defined area of illumination. Wi-Fi, on the other hand, utilizes radio waves that are widely broadcast even

Boost C-Store Profits by Cutting Hot Food Energy Costs Boost C-Store Profits by Cutting Hot Food Energy Costs Utilizing more energy efficient hot food roller grills and heated merchandizers can substantially increase the bottom line High energy bills are a problem faced by convenience store chains across the country, with 24-hour operations requiring constant lighting, heating, cooling and refrigeration. In the United States, a typical convenience store uses an average of 52.5 kilowatt-hours (kWh) of electricity per square foot each year. Compared to other commercial spaces, this is 3 times the average, with 24-hour locations utilizing up to 7 times the energy. Add to this the steady increases in electricity rates and peak demand charges and convenience store owner/operators are increasingly seeking out new ways to reduce daily energy usage. Although most of this focus has centered on refrigeration and lighting, one potential area for significant energy savings is too often overlooked: roller grills, heated merchandisers and soup warmers that make up the “hot food” section now in most stores. This type of equipment utilizes vast amounts of electricity to generate the heat for cooking or to reach the ideal holding temperatures to keep food warm. However, inefficient or aging equipment often draws unnecessary electricity, warms food unevenly and even increases food waste. As such, store owners and operators are making more careful decisions when upgrading equipment, including turning to more efficient “green” models. These units are designed to deliver up to a 20% reduction in energy savings, which equates to hundreds of dollars per unit each year in electric costs. “Convenience stores often run their roller grills and heated merchandisers all day and night, so the more energy efficient the heating the lower the operating cost and higher the profit,” says Gerard Mahoney, Senior Manager of Branded Products at Nathan’s Famous, Inc., franchisor of the iconic hot dog brand known worldwide. Lost Heat = Lost Profit Traditional roller grills run heating elements through about 8-15 hollow rollers (on which cylinder shaped food is heated, held, and served). The problem, however, is that heated air continuously escapes from both sides of the hollow rollers. This requires higher wattage heating elements, turned on more often, to maintain the temperatures needed for food safety. In contrast, the most energy efficient grills today seal the ends of the hollow rollers. This prevents the heated air from escaping, and allows the use of significantly lower wattage heating elements, saving up to 20% in energy costs. “The less heated air that escapes from the ends of the rollers, the less often the heating elements have to turn on, and the lower the required wattage,” says Mahoney. “That’s one of the reasons we turned to the energy efficient, sealed roller design of Creative Serving.” Creative Serving, a Union, NJ-based manufacturer of retail countertop food service equipment, utilizes heating elements with significantly lower wattage requirements than the industry norm. “For retailers with tight margins, saving a few hundred dollars a year in operating costs due to energy savings can be like found money in their pocket,” says Mahoney. Improved roller grill design addresses another vital issue as well. The large amount of heat escaping the ends of open rollers can cause heat variances of up to 50ºF in traditional roller grills. In contrast, roller grills with sealed ends can reduce these variances to less than 20ºF and distribute heat more evenly. “If you have a lot of heat variance in a roller grill, it can cause the product to over or undercook, to burn or fail to meet safety standards,” says Mahoney. “The roller grills with the sealed ends, however, provide a much more consistent temperature. This minimizes food waste and improves food safety.” More Efficient Heated Merchandisers To keep the widest variety of foods hot and ready to serve, heated merchandisers attractively present these foods at the counter in displays of various sizes. In this category as well, there are a number of ways to substantially lower operating cost by enhancing energy efficiency. Unlike open air merchandizers that heat food placed directly on an aluminum hot plate, one of the most energy efficient strategies is to use radiant heating in the shelves of an enclosed display that conserves the heat. For instance, Creative Serving’s Infinity Series of heated merchandizers uses this approach, while incorporating a durable stainless steel exterior and serving area. To achieve this, aluminum is sandwiched between the stainless steel surface and the heating element. This takes advantage of aluminum’s excellent heat transfer properties and stainless steel’s superior longevity, cleanability, and finish. Another energy efficient strategy, incorporated by the series as an option, involves using mirrored rear doors. These reflect heat back into the serving area, yet allow behind the counter staff to prepare, place, and store food items for customers to “grab and go” as needed. This approach enhances energy savings, hold times, and product display. When counter space is quite limited, very compact heated merchandisers can be deployed. However, traditional units can be underpowered in terms of heating. “In terms of heated merchandisers, the smallest countertop models sometimes offer just static heat with one heating element and a light bulb,” says Mahoney. So when Mahoney oversaw the development of a new Nathan’s Famous pretzel dog product for convenience stores, he turned to Creative Serving’s Mini, a 12” wide, three-shelf, heated merchandiser that can reach temperatures up to 180°F. To conserve energy, the unit’s convection heating system circulates air through small holes in the shelves. “The Mini saves energy while reaching and holding safe HACCP serving temperatures,” says Mahoney. According to Mahoney, another aspect that convenience store owners appreciate is the ability to easily place and remove magnetic signs, provided by their vendor, on the unit’s front. “To generate point of sale interest, they put magnetic signs advertising flavors, pricing and such on the front of the unit, then put them on the back for storage,” he says. “Any c-store or vendor using roller grills or heated merchandisers will be surprised at

Extending the Life of Wind Turbine Components Extending the Life of Wind Turbine Components Specialized PVD coatings and nitriding significantly increase the durability and lifespan of wind turbine components like roller bearings and planetary gears under metal-on-metal, high load conditions With the increasing demand for carbon-free renewable energy, more companies are turning to wind power as a source for their energy needs. Although this presents a good deal of potential for the manufacturers of wind turbines and their components, the technological challenges of providing a reliable product that operates with minimal maintenance or repair is increasingly daunting. That is because enormous forces are at work on the individual internal components. Turbine shaft bearings, planetary and sun gears, and rotating shafts, for example, operate under high load conditions that involve direct metal-on-metal contact, often in poor lubricating conditions. With components increasing in size, these forces only become more extreme. When this occurs, turbine components made of hardened steel or metal alloys can still break down as a result of extreme wear, scuffing, surface fatigue, pitting and galling. Given the sheer size of wind turbines, wind farm operators must bear significant costs for overhauls that often involve logistics involving cranes for on-site repairs. “When you have to bring a crane to change the main shaft bearing, for example, it is not only the cost of the new bearing but also the total work to exchange the part, says Dr. Florian Rovere of Oerlikon Balzers, a company that produces specialize PVD coatings for components in North America. “It can quickly become $100,000 or $200,000 for the overhaul,” adds Rovere. “So all of a sudden, your green energy becomes super expensive, which is why wind farm operators really want to extend the longevity of the components as much as possible.” To address this issue, coatings and surface treatments can significantly extend the service life of wind turbine components. Today, this is being accomplished through the application of specialized physical vapor deposition (PVD) coatings and nitriding treatments that increase surface hardness and durability. By applying coatings optimized for these types of punishing environments, components benefit from increased surface hardness and a much lower coefficient of friction. As a result, these critical parts do not have to be replaced as frequently, if at all, reducing maintenance and unplanned downtime while improving wind turbine performance. PVD Coatings Physical vapor deposition encompasses a wide range of vacuum deposition methods. It essentially covers components with thin coatings to increase their surface hardness and durability, lower the friction coefficient and resist corrosion. By applying components with PVD coatings designed for such demanding conditions, not only is the surface hardness and durability increased, but essential parts are far less likely to fail, if at all. As a result, maintenance and unexpected downtime is drastically reduced. A specialized PVD coating that is particularly effective is BALINIT C, which can be applied in thicknesses of 0.5 to 4 micrometers on roller bearings and gear parts. The WC/C ductile carbide carbon coating has a high load-bearing capacity, even when used with insufficient lubrication or dry contact. Due to its low-friction coefficient, the coating can drastically reduce fretting corrosion and pitting. By forming an effective barrier between metal-on-metal contacts, the coating reduces metal structural damages such as white etch cracks and fatigue failure. According to Rovere, there are alternatives to PVD coatings that are at time used on wind turbine components, like black oxide. Black oxide is a coating produced by a chemical reaction between the iron on the surface of a ferrous metal and oxidizing salts. After a post-treatment with oil, the surface provides protection against corrosion, improved lubricity and prevents galling during metal-to-metal interactions. However, black oxide is not very durable and can be worn away quickly in repetitive, high load applications. Nitriding There are limitations to the size of products that can be coated with PVD, such as the ring gears in modern wind turbines that can measure up to 2-3 meters in diameter. For these types of large gears, Rovere says a nitriding process can be used instead to increase the surface hardness of the metal. “Nitriding is a heat treating process that diffuses nitrogen deep into the surface of a metal to create a case-hardened surface,” explains Rovere. “Because it is not a coating, it does not affect the overall dimensions of the component.” Although traditional gas nitriding costs less, plasma nitriding has the advantage of making the treatment more precise by minimizing warpage and distortion while achieving a higher load-bearing capacity. In an FZG pitting test BALITHERM IONIT, a plasma nitriding process from Oerlikon Balzers, exhibited five times less roundness deviation and seven times better planarity than gas nitriding on a 2-meter diameter ring gear. Another potential application for plasma nitriding is for treating the surfaces of large bearing cages used with wind turbine bearings to increase the sliding wear resistance against the rollers. The process can be used on components up to 3 meters in diameter, 10 meters in length, weighing up to 40 tons. “Compared to gas nitriding, the tolerances for roundness, planarity and parallelism can be adhered to much better, even with such large parts as the ring gears, and that is of great importance for the service life of a system in which enormous forces are at work simply because of its size,” says Rovere. For more information about coating or nitriding solutions for components with Oerlikon Balzers, call (408) 375-4408, e-mail: balzers.components@oerlikon.com; or visit www.oerlikon.com/balzers

Hotels Reduce Heating/Cooling Bills Up to 30% by Adding Inner Insulating Windows Hotels Reduce Heating/Cooling Bills Up to 30% by Adding Inner Insulating Windows Innovative approach enhances insulation and stops air infiltration without replacing existing windows For hotels, motels, and resorts, insufficiently insulated windows can be a serious problem that literally sends profits “out the window” in the form of excessive heating and cooling bills. When it is warm inside the hotel and cold outside, window panes will transfer heat by thermal conduction so additional heating is required to keep guests comfortable, and a similar process is involved when it is hot outside and cool inside. Air leakage through window seals that crack over time worsens the problem, particularly in harsh weather. While single pane windows transfer the most heating and cooling, even dual pane windows may be insufficient to tame high utility costs. Now hospitality managers are looking to an innovative approach that adds an inner insulating window to existing windows. This can reduce heat loss by 77% or more for single paned windows, and heating/cooling bills by up to 30%, while stopping air infiltration for further energy savings and greater comfort. Adding the inner window, in fact, provides an additional layer of insulation with better insulation values than the best double pane windows. The same practice will also substantially reduce unwanted external street noise to provide guests a better night’s sleep and a more peaceful environment. Cutting Heating and Cooling Cost Two factors are vital to keeping hotel heating and cooling costs from escalating: the window’s basic insulation value and preventing air infiltration through and around the window’s seals. Window Insulation Value The window’s basic insulation value is largely a factor of the air pockets or bubbles that adhere to panes of glass. These serve as insulative barriers to the transfer of heating or cooling by thermal conduction. “Air pockets or bubbles ‘adhere’ to glass, which is the major reason glass has any insulating value,” explains Randy Brown, President of Soundproof Windows, a national manufacturer of window energy efficiency and soundproofing products. “The more such air bubbles adhere to the glass, the better the insulation.” In practice, with a single pane of glass there are two air bubbles, one on each side of the pane. With dual pane units, there are three bubbles, one on each side of the panes and one between them. However, according to Brown, with a second window acting as an insulating window, there are actually five bubbles when used with a single pane window if the air space is more than 1 inch. As an example, an air space of 2-4 inches usually separates the existing window and the Soundproof Window, which serves as a “second insulative window” that can be installed easily in front of the existing window. The product is designed specifically to match and function like the original window, no matter its design or whether it opens or closes. In terms of measuring energy efficiency, the R value of a window indicates its resistance to transferring heat. Better windows have higher R values. Adding such a “second window” can actually increase the hotel window’s insulation R value by 2.5 or more, dramatically reducing heat loss. This reduces window heat loss by about 77% for single pane windows. It can substantially improve insulation values for dual pane windows as well. A window with a single pane of glass, for instance, has an R value of 1.15. One with a dual pane of glass, with ½” air space, has an R value of 1.81. However, an existing single pane window with a “second insulative window” would have an R value of 3.84; and a double pane window, an R value of 4.40. Preventing Air Infiltration Air infiltration due to leaky window seals often causes cold drafts and temperature differences within the hotel room. To compensate for these cold drafts, guests or hotel management often set the thermostat higher. Due to wind and temperature cycling, particularly in extreme climates, most window seals typically start leaking significantly within a few years. To prevent such air infiltration, however, Soundproof Windows frame seals are held under a constant tension, using custom made tempered stainless steel springs that actively squeeze down on the window. This means the window seal is flexible, constant and always working. When used in combination with existing windows, in fact, the second window seals effectively eliminate any cold drafts or air infiltration, further increasing energy savings. In terms of reliability, such seals are guaranteed for a 50 year lifespan. Silencing External Noise The same approach of adding an inner second window can also do double duty for hotels by preventing loud external noise sources, such as traffic, honking, or pool play, from penetrating the windows to disturb guests’ sleep or peace of mind. The inner window essentially reduces noise from entering on three fronts: the type of materials used to make the pane, the ideal air space between original window and insert, and improved, long-lasting seals. The combination can reduce external noise by up to 95%. “The first noise barrier is laminated glass, which dampens sound vibration much like a finger on a wine glass stops it from ringing when struck,” explains Brown. “An inner PVB layer of plastic further dampens sound vibrations.” Air space of 2-4 inches between the existing window and the Soundproof Window also significantly improves noise reduction because it isolates the window frame from external sound vibrations. The company’s spring-loaded seals in the second window frame comprise a third sound barrier. “This puts a constant squeeze on the glass panels, which prevents sound leaks and helps to stop noise from vibrating through the glass,” explains Brown. When the 11-story, 144-room Four Diamond Hotel in downtown Houston protected a number of its windows from external noise with Soundproof Windows, the energy savings were substantial. A detailed one-year study showed the hotel saved $2.11 in energy savings per occupied room night. This amounted to 15.7% per occupied room night for

Shining a Light on Rack Selection Shining a Light on Rack Selection Member-owned public utility cooperative consolidates operations into warehouse with forklift resistant rack Even before Clay Electric Cooperative sought to build a new warehouse to consolidate maintenance materials from various storage facilities into one location, the north Florida member-owned cooperative was determined to dramatically improve logistics, reliability and productivity. However, achieving this required resolving the most pressing issues encountered at its existing facilities, and engineering a solution that would lower costs and reduce downtime in the future. The co-op, which serves approximately 170,000 accounts and services an area that stretches into 14 counties, had ongoing issues with forklifts running into and damaging the racking. Bidding for the job had to be open but would come down to more than the lowest bid. In choosing value over price alone, the co-op was looking for the best long term solution. “The co-op wanted to invest from day one in the proper safety gear to get the most life out of their equipment, since the value of their purchase and the safety of their operations are paramount,” says Buddy Chadwell, President of Kardex Storage, a material handling distributor in Florida. Because the new warehouse would not require high-volume traffic, like a distribution center for example, employees would not be dedicated, full-time forklift operators. In the past, consequently, this had increased the instances of forklift impact related rack damage, so the racking had to be capable of withstanding unavoidable accidents with minimal maintenance. In such cases, increasing rack resistance to impact can improve safety and operations while reducing the total cost of ownership including repair and premature replacement. Generally, there are several ways to achieve this, which involve choosing the appropriate racking materials and options. “Typical rack that uses three sided upright columns with an open back, called open back roll form rack, is more susceptible to potential accidents by operators lifting a load too high and backing out,” says Chadwell.  “This can place twisting, torsional loads on the rack that can shorten its lifespan and even lead to it tipping over. It is seldom the best choice when the structure must endure frequent or long term forklift impact.” A better choice is to opt for a cost effective racking system that is designed to withstand the increased impact, and then supplement the most impact prone areas with additional protection. In search of a solution, Chadwell conferred with Steel King Industries, a national manufacturer of storage rack and material handling products, whose engineers reviewed the co-op’s warehouse layout and blueprint. The engineers recommended a tubular upright rack product, with a robust four-sided column structure that offers a more suitable choice at a similar price point. For the project, the co-op decision makers chose SK2000 pallet rack, a boltless, closed tubular upright product by Steel King. Compared to open back roll formed columns, the closed tubular uprights are 44 times more torsion/twist resistant, with 250% greater frontal impact resistance and 68% greater side impact resistance. All beams are constructed of high-strength (55,000 p.s.i. minimum) steel, and holes are placed on the column’s face, not the corners, minimizing strength loss. “The tubular rack is much more resistant to rack movement and twisting than open back channel designs,” says Chadwell.  “This translates into a much longer usable lifespan and more operational uptime with minimal maintenance.” To make its storage racking system even more impact resistant, Clay Electric also implemented an innovative, adjustable, boltless rack column protector, called Snap-Guard, which safeguards the upright rack column from forklift damage.  Constructed of structural angle, with a unique 4-rivet connection that automatically locks into the upright column, it can be adjusted and removed as needed to protect the desired storage level. “Instead of a typical bolt-on design, the snap on protector snaps into the rack’s tear-drop holes, which makes it very easy to install and adjust,” says Chadwell. Since a rack upright’s first 6” to 12” of column from the floor is also prone to fork truck impact, particularly at end rows and intersections where maneuvering is tight, Kardex Storage also recommended and installed Guard Dawg guard rail rack protection. The guard rail, constructed of high-strength steel angle, protects upright columns and comes in right, left or double ended guards so it is fully compatible with most end row racks. According to Chadwell, there were distinct advantages to this turnkey approach toward integrated racking versus a less comprehensive piecemeal approach. “Too often when a company purchases rack and then tries to mix and match guardrail or other accessories from third party sources, there can be compatibility or accountability issues,” says Chadwell. “When buying from integrated manufacturer like Steel King, it is all engineered to work together, with one company taking full responsibility if support is ever needed.” As for the end result, Chadwell says, “The closed tubular selective rack, with its accompanying guardrail and column protection, is designed to last decades longer than typical open back rack, with less maintenance and more uptime.” For its part, the co-op is already experiencing the benefits of the extra engineering that went into its new warehouse, along with its selective rack. With more than 13,000 miles of distribution and transmission lines, the co-op has received a superior Average Service Availability Index of 99.95 percent, a measure of reliability commonly used by electric utilities. By making these types of key, targeted improvements to increase uptime, productivity and safety, Clay Electric Cooperative expects to further build on its stellar reputation and overall index rating. For more info on optimizing warehouse storage and production, contact Steel King Industries, 2700 Chamber St., Stevens Point, WI 54481; call 800-826-0203; email: lfraser@steelking.com or visit www.steelking.com

A Monolithic Approach to Primary and Secondary Containment A Monolithic Approach to Primary and Secondary Containment Advanced flexible polyurea coatings, applied directly to the substrate or pre-applied to geotextile liners, provide seamless containment for facilities and field applications When used for primary or secondary containment, traditional coatings have been too inflexible and not sufficiently elastic to accommodate ground, concrete or metal substrate movement. This deficiency can lead to cracks or holes developing in both the substrate and the coatings, which can compromise containment. However, the formulation of tough, monolithic, flexible coatings such as polyurea are now resolving this issue for contractors, engineers, and facility managers. When applied directly to concrete or metal surfaces, polyurea not only reinforces and protects the underlying substrate but can also bridge gaps or cracks of 1/8” or larger. Furthermore, polyurea is now being pre-applied to geotextile liners that can be quickly rolled out in sheets to protect more heavily damaged surfaces or for use in field applications such as dirt or gravel pads at drilling sites. Once installed, applicators need only coat the seams of the liners to create a monolithic surface that is ideal for containment. Containment Requirements Whether at refineries, industrial plants, or other manufacturing facilities, federal and state regulations mandate the use of primary and secondary containment systems to keep toxic or hazardous substances from escaping into the ground and potentially entering the water supply. Implied in this requirement is the understanding that primary containment (typically via a concrete or metal storage vessel that holds chemicals or liquids) is not foolproof. Though durable, metals corrode, concrete cracks and is porous as well, so will leach liquids if uncoated. This requires secondary containment, which often takes the form of concrete pits with barriers installed around the perimeter of a tank or other storage container. To protect these structures, coatings such as epoxies, tars, and polyurethanes are often applied as an added barrier of protection. However, these traditional coatings are frequently inflexible when cured and can crack along with the concrete. “Typical coatings do not hold up well to substrate movement or daily, seasonal, or process-related thermal expansion and contraction, which can lead to cracks and leaks,” says Jim Collins, co-owner of South Penn Resources, a company that creates containment systems in the Pennsylvania region. After considerable research and testing, Collins says he turned to an advanced polyurea system from VersaFlex, a leading manufacturer of spray applied polyurea for primary and secondary containment. When applied to substrates such as concrete or steel, the spray-applied waterproof coating creates a durable, seamless, flexible, protective barrier that stops leaks and strengthens the integrity of primary and secondary containment systems. The coating exhibits superior physical properties such as hardness, tensile strength, as well as crack bridging and elongation up to 400%, to create a robust, industrial-grade protective lining. “Polyurea can bridge cracks as well as flex at a rate similar to concrete and steel,” says Collins. “This not only helps it last but also seals the concrete so it does not absorb contaminants if there is a spill inside the contained area.” When compared to traditional coatings, Collins also appreciates the quick return to service possible when spraying the polyurea system for containment. While traditional coatings such as cementitious, epoxies, tars, and polyurethanes will prematurely fail if not installed under a relatively narrow range of temperatures, polyurea is designed for installation and use from -40°F to +350°F. It sets and cures quickly and will withstand decades of freeze-thaw cycling, as well as wide variations of temperature and humidity. “After spraying the polyurea, return to service is almost instantaneous, which can make a big difference in minimizing production downtime,” says Collins. “We coated about 8,000 sq. ft. of concrete in 12 truck-offloading areas that required drive-in containment with VersaFlex polyurea. Within minutes of spray application, trucks were safely driving across it.” Fast, Effective Containment in the Field Although spraying polyurea directly to the substrate has many advantages, for containment over soil, gravel, or even concrete that is too damaged to be effectively rehabilitated, pre-sprayed composite panels offer superior protection. This solution is particularly suited to field applications that must be able to endure heavy traffic from trucks loading or unloading materials. Although plastic liners that are seam-welded together are often used for such applications, they are more easily punctured and can bunch up under heavy use. “For primary containment at oil field drilling sites, we used to put various plastic systems on the well pads, but we moved away from that because plastic was not durable enough,” says Collins. Repairing plastic liners also presents a problem at the seams, when damaged areas are cut out and new sections welded in, says Collins. “The result is a patchwork liner with seams that are prone to failure due to improper welding as well,” he says. As a solution, Collins turned to geotextiles with pre-applied polyurea for its significant advantages in durability and reusability. “Polyurea products are so much more durable than plastics for containment systems,” says Collins. “When needed, we can custom apply more polyurea millage to geotextile panels and berms to accommodate even the heaviest truck use and vehicle abuse.” To verify the strength of the polyurea coating on containment mats and berms, in fact, Collins conducted a number of tests. “I ran an 11,000 pound skid loader onto a containment mat, stood the forks straight up and tried to puncture it – but it did not puncture through,” says Collins, who put the test video on South Penn Resources’ website. “We also ran 6,044 fully loaded water trucks across a containment system and it withstood it with zero holes and no compromise to the liner.” Collins credits both the durability of the VersaFlex polyurea as well as its extended recoating window for the ability of his company to extensively reuse its containment systems. “To reuse a containment system, we’ll cut it up into rolls, roll it up and move it. Then we’ll take it back out, respray certain

Switching to Cast Polyurethane Parts for High Impact, High Wear Applications Switching to Cast Polyurethane Parts for High Impact, High Wear Applications High-performance polyurethanes combine the advantages of plastics, metals and ceramics with resiliency of rubber parts Although ship and boat building design engineers have traditionally specified parts made of rubber, plastic, or steel when durability is required, many are considering a new alternative for the most demanding, high-wear, abrasion and impact applications: cast polyurethanes. Cast polyurethanes, also broadly referred to as urethanes, are tough, elastic materials that combine many of the performance advantages of high-tech plastics, metals and ceramics along with the resiliency and flexibility of rubber parts and are ideal for ship/boat building components. Unlike its closest counterpart, rubber, which is prepared as sheets or loaves before being molded in a high pressure press, urethanes can be poured as a liquid mixture into less expensive, low pressure molds. Using this technique, complex mold cavities can be filled without high-pressure molds and presses.  This provides a multitude of advantages, not the least of which are lower tooling and production costs than both rubber and plastic molding. In terms of performance, cast polyurethane parts are often lighter in weight than alternatives and are not brittle and will not crack like plastics under stress or extreme temperatures. To be sure, cast polyurethane parts are not new. Nonetheless, awareness of the potential for this type of material has largely remained under the radar. This can be attributed to several factors, not the least of which is a general lack of understanding of the options and formulations. One does not simply specify a polyurethane part, for example. There are many formulations – some proprietary – that can be used to manipulate a range of variables such as hardness, resilience, spring rate, and chemical resistance. For this reason, ship/boat building design engineers interested in a possible switch to polyurethane from plastics, steel, ceramic or rubber parts are often best served by seeking out the assistance and guidance of experts in urethane formulation. Customized Urethane Parts in Action When a Dutch ship builder required a new slipway liner that could absorb the impact and abrasion of a speedboat exiting and entering its offshore patrol vessel through a rear bay, for instance, it selected a specially formulated polyurethane from Argonics, one of the U.S.’s largest producers of wear-resistant urethane products, over other materials. The urethane liner replaced a nylon plastic liner, which tended to damage speedboats because it was too hard, according to Lars Muller, owner of Muller-Beltex, a Netherland-based parts distributor to various industries, who was involved with the project. “The liner had to resist impact, abrasion, seawater, and UV exposure yet allow the speedboat to slide in and out of the bay without damaging the speedboat or the patrol vessel,” says Muller. To maximize durability and cushion the impact of the speedboat entering and exiting the offshore patrol vessel’s rear bay, Argonics collaborated with the Dutch shipbuilder and Muller-Beltex to engineer a urethane slipway liner comprised of two layers of material each with a different durometer, a measure of hardness. According to Muller, Argonics came up with the idea of creating a dual durometer liner to better withstand the inevitable wear and impact. “The urethane’s harder top layer has more resistance against cutting and tearing, while the bottom layer is softer to better withstand the impact of the powerboats,” says Muller. He adds that Argonics’ expertise in urethane formulation helped to optimize the material for the necessary characteristics, while creating strongly bonded layers that would not separate. “With their expertise, along with CAD, Solidworks, and prototyping capability, they can design a part in urethane to match any other substance or requirement,” says Muller. Continued collaboration between the three companies has resulted in additional product refinements. “We recently beveled the slipway liner’s edges to ensure that no seawater or sand can get behind it,” says Muller. “We also hardened the urethane at the bolt holes to better hold the screws and attachments where they fit the liner. To ease installation in the field, we added countersunk areas in the liner to match the exact positions of the part’s countersunk boreholes.” “With urethane, you can combine strength, resilience, and lifetime durability in one product,” adds Muller. “The end user is very enthusiastic about the slipway liner. The application is now fully accepted by the shipyard and a standard product in their ship line.” Proprietary Formulations Although urethane producers can create customized formulations to accommodate varying characteristics such as hardness, resilience, and spring rate, some also have developed proprietary formulations. Kryptane is an extremely wear-resistant material for applications where sliding, impact, abrasion, or corrosion occurs regularly. Examples include impact-and abrasion-resistant plates; blasting curtains and screens; chute, bin and hopper liners; pipe, fitting and valve liners, vibration pads, seals and gaskets; as well as truck bed liners, wheel chocks and crossover pads. Instead of choosing to make parts via injection molding, ship/boat builders will often choose the method of poured urethane parts from Argonics because they do not want to pay the high cost of injection molded tooling. Urethane is usually much more cost effective, whether for one-off or higher volume parts. For more information contact Argonics, Inc., 520 9th St., Gwinn, MI 49841; visit www.argonics.com; call 800-991-2746; email information@argonics.com.

Bathroom Remodeling Challenges in the Hospitality Industry Bathroom Remodeling Challenges in the Hospitality Industry Selecting experts that specialize in hotel/motel bathroom remodels can save on costs while addressing industry-specific concerns over disruption and room availability During a hotel stay, guests expect their bathrooms to have a fresh and modern look. Old, dated or damaged bathtubs, wall surrounds, vanities or toilets reflect poorly on the hotel’s brand. As such, many hotels regularly replace bathroom components to maintain customer satisfaction and earn positive reviews and loyalty in return. For the hotel industry, however, remodeling bathrooms is not as simple as hiring a general contractor that subcontracts the work to a local crew. While providers of this kind abound, there are many industry-specific considerations that are best served by those who already have extensive experience working with other hotel chains. These concerns include reducing or eliminating construction noise, noxious odors or dirt/dust than can disrupt other guests. The work must leave a lasting impression while, at the same time, be completed within budget and as quickly as possible to return rooms to service. In addition, there are economies of scale. Because renovation is typically completed in blocks of rooms, installers that regularly service the hospitality industry can often provide better pricing on items – for example, acrylic bathtub liners – than those that primarily serve the residential home market. “There are local companies that I can call right now where an acrylic bathtub liner may cost me $1000. But I can get one shipped from one of the more established companies for half that price,” says James Rutherford, Chief Engineer at the Hilton Cincinnati Netherland Plaza hotel, who manages the daily maintenance operations for the National Historic Landmark that opened in 1931. There are other potential benefits as well. Hotel-specific providers are often already certified to work with existing chains and tend to keep specifications of commonly installed items on file. “There are quite a few reasons to go with a company that already knows the industry, understands our concerns, and can complete the work quickly and quietly,” says Rutherford. Bathtubs – Replace, Refinish, or Reline Bathroom remodeling can involve several projects, but the bathtub is always a key component. When it comes to updating a worn-out bathtub, three options are available, all varying in cost, labor, and potential for guest disturbance: replacing, refinishing, and relining. Replacing an old bathtub is an expensive, labor-intensive, and time-consuming project that often involves demolition and damage to the surrounding walls and floor finishes. Water supply lines and pipes may also need replumbing. Rutherford explains that for a historic hotel, bathtub replacement is rarely an option. “We wouldn’t consider ripping out the tub unless we were doing a full renovation of the room because our walls have the original tiles. Replacing the walls is just not cost effective because of the rebuilding cost,” he says. In addition, replacing a bathtub can take several days and can be extremely noisy and dusty, often leading to complaints from guests. A second option involves the refinishing, or re-glazing, of the existing bathtub. The process includes sanding the current coating, filling chips with epoxy, followed by coating and polishing. While this option costs less than a full replacement, it can take several days to complete. Rutherford adds that although re-glazed bathtubs look beautiful, the finish only lasts a few years. Another downside is the obnoxious odors released during application. “You’ve got to block rooms and take them out of your inventory. Even though you go through all the proper processes and ventilation, the smell lasts for several days,” explains Rutherford. The third option is to use an acrylic bathtub liner installed on top of the existing bathtub, therefore creating a new bathtub surface that can last for decades. Made from durable materials, acrylic bathtub liners feature high gloss, minimal porosity, and excellent scratch resistance – all of which simplifies cleaning. Installation is a critical aspect with any acrylic bathtub liner. Some manufacturers, such as American Bath Remodeling, have developed their own proprietary and patented installation process to ensure a complete, watertight fit. The Scottsdale, Arizona-based company has been serving the hotel industry for almost 40 years and has remodeled more than a million bathrooms over that span. According to Rutherford, he first used American Bath Remodeling to install acrylic bath liners in half of his 560 hotel rooms in 1993. He now orders replacements as the need arises. Because the acrylic bathtub liner comes pre-fitted, installation takes less than two hours. With no drying time required, the bathtub can be used almost immediately after installation. Of all the options, relining a bathtub is the least disruptive and does not affect overnight room availability. Wall Surrounds Wall surrounds are another remodeling option. Manufactured from non-porous and stain-resistant DuraBath® SSP, cultured marble, and even granite, wall surrounds are available in many color and pattern options. Installed over existing walls, including tile, this is an excellent option for swift installation with little downtime or guest interruption. Longtime owner of the Days Inn in Niles, Ohio, Dick Patel decided wall surrounds were the ideal solution for a major bathroom remodel he embarked on shortly after acquiring the property. According to Patel, the installers were professional, quiet and did not disturb any guests. “There was no noise or breakage during the installation,” says Patel. “Any minor trimming required was done outside, and American Bath Remodeling was able to put the liners right on top of the existing tiles.” The installers completed 10 rooms a day, for a total of 80 rooms, and did not affect overnight room availability. Patel expected the wall surrounds to last 15 years, but now, almost 30 years later, he says they still look like new. “The walls are easy to keep clean and don’t require abrasives,” says Patel. “The original shine is still there.” Before starting any remodeling project, Patel recommends that hotel operators ask others for references and inquire about how much they like the products and the installer. When possible,

Optimizing Pallet Flow Performance Optimizing Pallet Flow Performance Following a few pointers can help to maximize productivity, extend equipment longevity, and improve safety When it comes to pallet racking, flow storage is essential for managing perishable, time-sensitive products on a first in, first out (FIFO) basis. Since its design eliminates aisles and fills the space with additional pallets, it provides many times more storage than selective rack. In addition, forklift travel is greatly reduced because drivers only need to place and retrieve loads from either end of the system – significantly reducing operating costs, maintenance, and accidents. Better space utilization also minimizes the need to light, heat and cool the facility, further decreasing expenses. While the advantages are numerous, due in part to its design and moving parts, there are additional considerations for those operations looking to improve production with a flow storage system. These 10 tips can help prolong the life of the equipment, cut maintenance costs, and enhance safety with the proper design, selection, and operation of the system. Understanding Flow Storage 1) Consider flow storage when efficient storage is critical and space limited. Flow storage is useful in many applications including ambient, cooler, and freezer environments, raw materials receiving and storage, work-in-process, buffer storage, finished goods and cross docking. It is also often successfully used in pick module and automatic storage and retrieval systems (AS/RS). 2) Understand how flow storage works. Unlike traditional selective rack, a pallet flow storage system has two parts: a static rack structure and dynamic flow rails. The flow rails are set at an incline in the rack structure, which allows loads placed on one end of the rack to move by gravity down to the unloading end. Rollers let the loads move smoothly while self-energized speed controllers act as gentle brakes. As a load is removed, the loads behind it move forward automatically. However, due to pallet flow system design as well as moving parts, there are additional things to consider. Pallet Flow Design Considerations 3) Choose a design that can adapt to both current and future needs. Because budget and inventory requirements change at both the facility and corporate level, it is wise to select a flow system with a design that can grow as your business needs grow. “With flow systems, bays can be added to groups and the bay widths and depths can be easily be expanded to hold additional inventory, which allows you to buy for your current needs and expand later,” says Ryan Wachsmuth, Dynamic Storage Sales Manager at Steel King Industries (steelking.com), a major designer and manufacturer of warehouse material handling, storage and safety products. 4) Ensure that the flow storage system has enough rack strength. To be even more accommodating of future needs, such as higher or heavier pallets, Wachsmuth also advises selecting a flow system that provides vertically adjustable beams and ample strength. “You can always re-profile your flow rack to handle higher, heavier pallets if you design for it,” says Wachsmuth. “Let’s say you use a 48” high pallet today, but decide later that a 60” high pallet is more efficient because you want to add two more levels of ice cream to each pallet. A system with vertically adjustable beams would allow you to do it, provided you have the rack strength.” 5) Ensure that capacity matches capabilities. When you design your flow storage system, you have to know your warehouse’s capabilities and limitations. For instance, know how low girders, trusses, warehouse lighting, HVAC ductwork, and sprinklers and fire suppression lines hang, and determine how much clearance is required. In addition, before you begin loading the system it is critical to consult with the local fire marshal and get their approval on the design and layout to ensure it meets fire code regulations. Safety and Productivity 6) Plan for expected flow system use. If your warehouse facility is heavily used, forklift drivers are more prone to impact racking. Because a flow system’s entry uprights tend to receive the most damage from forklift impact, Wachsmuth advises working with a vendor that offers a range of reinforced upright options. Guardrail, rack and column protectors, as well as weld bumpers (angles welded to the aisle side beams), can also help to protect the pallet flow rack system from forklift impact. If impact occurs, these safety items can be quickly replaced without having to close off lanes or bays. Facilities should also consider holding extra rack inventory, such as uprights and beams, so any rack damage can be repaired immediately. This keeps production going without waiting for a supplier to ship replacement parts. 7) Consider facility requirements and standards. For industries whose products require a high hygienic standard, such as for food, dairy, beverage or pharmaceutical products, it is important to avoid any racking with holes, open spaces, or flat spots where food or liquid can accumulate, potentially leading to rot, mold, or contamination issues. In these cases, to better meet FDA or USDA regulation, Wachsmuth recommends that flow systems use a sanitary structural channel rack design. As an example, Steel King offers the SK3000, which is modified with angled tubular cross bracing. The angled surfaces and closed tubular construction leads food or liquid that falls on the rack to flow off, thus preventing potential hygienic or contamination issues. 8) Ask for a pawl anti-backup device to ensure safe unloading and proper flow. When forklift drivers unload a pallet from the flow system discharge end, they typically perform a maneuver called a ‘plug.’ That is, with the pallet they pick up, they push the next pallet in the flow lane to get the row of pallets to properly flow to the unloading end. When forklift drivers perform this standard maneuver, a pawl anti-backup device can help prevent a pallet from unintentionally being pushed off the loading end. A pawl can also assist productivity by helping forklift drivers keep pallets safely flowing to the unloading end of the system. Completing the System 9) Seek single source accountability. Designing and installing a pallet flow system could involve a separate pallet

A Deeper Look at “Precision” Toolholders A Deeper Look at “Precision” Toolholders Quality of machining and quality control differentiates “standard” toolholders from precision Although toolholders are known to be critical components in the precision machining process, the unique details that differentiate a “standard” toolholder from one that is designed for more precise, high speed work can be subtle. Like the parts they are used to create, precision toolholders are machined to exacting tolerances to create the optimum fit within the spindle, concentricity and balance. The more precise the work, the more these factors come into play. If not properly machined, a toolholder that doesn’t fit securely in the spindle or is improperly balanced can vibrate, wobble or fret, leading to out-of-tolerance parts, oversized, tapped holes and inconsistent, unrepeatable results. As such, there is value in taking a deeper look at the elements of fit, balance, application of coolant, and other aspects of precision toolholders. For many, doing so may be the key to maximizing the speed and accuracy potential of their machining centers. AT3 Certified Tapers The toolholder is the essential connection between the machining center and the cutting tool. The toolholder fits into and is secured by the machining center’s spindle, and in turn, secures the cutting tool such as a drill or end mill by clamping onto its shank. Toolholder tapers are often conical, including CAT and BT taper specifications. A different kind of taper, HSK, is not tapered at all, but instead includes a variety of flanges for securely locking the toolholder in place. For free-releasing toolholders with tapered flanges, the quality of the fit between the spindle and the holder is critical for accurate location and proper hold. Unlike those that require a drawbar, free-releasing varieties must maintain firm contact over the entire conical surface so the forces of drilling can be resisted and the tool remains in the spindle when idle. A holder that is too loose causes the tool to wobble or fret, creating imperfections in the end product and reducing tool life. “If the toolholders don’t seat in the machine properly…you can’t make a good product,” says Ron Fulks, tool room manager for National Oil Varco. The company manufactures reciprocating pumps used in midstream oil and gas transportation. According to Fulks, he began purchasing precision toolholders for several CNC boring mills after switching from tension compression tapping to a more rigid approach. “The tapping procedure is very important, because if there is runout it will make the tap cut bigger, so your hole won’t gauge,” says Fulks. The items he purchased included tapered toolholders for the taps as well as straight ID shank toolholders for end mills for several CNC boring mills. To ensure the toolholders would fit optimally, Fulks says he selected Collis Toolholder. Founded in 1901, the company manufactures and distributes over 4500 tools and toolholders. For its tapered toolholders, Collis is known for exceeding the industry “AT” standards for precise fit in the spindle. These standards are a specification of ANSI/ASME standard (ASME B5.50-2009) and indicate the tolerances that must be met in relation to the taper angle. Since most CNC machine spindles are manufactured to an AT2 tolerance, toolholder manufacturers often provide tapered products that are “AT3 or better.” However, while some providers claim to offer AT3 toolholders, Collis is the only manufacturer that goes through a process of quality control testing to certify and document its products actually meet the specification. Precision balancing for high speed machining When RPMs increase to 20,000 to 30,000 or higher in high speed machining, the toolholder must be balanced more precisely. Starting at about 8,000 RPM, the spindle begins to expand and can diminish the contact with the toolholder taper. This can result in vibration that leads to out-of-tolerance parts. The generated “whipping effect” can stress spindle bearings and ultimately reduce tool life. To prevent this from occurring, manufacturers often specify the level of unbalance by a G number with units in millimeters per second (mm/sec). For these reasons, machine-tool spindles and machine-tool parts usually are specified with vibration levels of G2.5 and G6.3. According to Waylan Deen, President of Erosion Technologies, concentricity along the centerline is the most critical characteristic of a toolholder. Otherwise, runout can alter the size or width of drilled holes or slots, ruining the cut. Imperfections such as these can be particularly costly when working with titanium or other exotic metals, often used in the aircraft industry. Since the defects cannot be repaired, the entire piece must be scrapped. Since 2005, Erosion Technologies has added three high-speed vertical machining centers to complement its wire EDM services. Deen also turned to Collis for tapered and standard end mill holders and quick-change toolholders for taps, which are balanced to the higher G2.5 standards. “I purchase from Collis because the toolholder are always spot-on in terms of balance and concentricity,” says Deen. Coolant-induced toolholders Machining centers designed for through-spindle coolant application have been standard for years. When used in boring or tapping operations with hollow cutting tools, excess metal scrap and shavings must be flushed from holes and bores. However, when there is no provision for feeding coolant through the machine spindle, there are alternatives where coolant can be introduced through the collar of the toolholder. This not only minimizes overheating and distortion of the workpiece but also greatly extends tool life. Although coolant-induced toolholders are available on the market, they can be quite expensive. Fortunately, there are options that cost much less – in the several hundred dollar range – from manufacturers such as Collis for Cat V-Flange, BT, NMTB, Morse Taper and R8 style shanks. Difficult-to-Find Toolholders For machining operations that have been around for a long time there is a high likelihood that equipment purchased decades ago is still being used – even if newer CNCs have been added to the mix. This can include drill presses, manual milling machines, and automotive transfer line equipment. If this is the case, the necessary toolholder may be otherwise difficult to obtain

Multi-Purpose Abrasive Nylon Brush Becomes Staple in Machine Shops Multi-Purpose Abrasive Nylon Brush Becomes Staple in Machine Shops Abrasive nylon brushes prove to be flexible and useful finishing tools for deburring, edge breaking, surface finishing and corrosion removal on metal and alloy workpieces In contract manufacturing, removing excess material that remains on a metal part after fabrication is an important finishing step. Despite utilizing increasingly sophisticated machining centers, however, much of the secondary finishing work is still performed by hand using oscillating tools, grinders, files, abrasive hand pads and wire brushes. This labor-intensive approach only serves to drive up costs – for both the shop and, ultimately, the customer – while yielding inconsistent results. For those parts that do not meet the specifications, reworking may also be required. As a result, contract manufacturers are turning to new finishing tools that can be easily integrated into automated machinery, CNC machines, transfer lines or robotic cells in an effort to reign in costs and achieve more consistent results. These new options include abrasive nylon brushes that can be used for a variety of finishing operations including deburring, edge breaking, surface finishing and even light corrosion removal. In some cases, these multi-purpose tools can also eliminate machining operations traditionally performed by chamfer tools and face mills. “We have implemented abrasive brushes on every CNC machine we have, which includes our live tool lathes,” says Eric Sun, Founder of Orange Vise Company. In addition to manufacturing CNC machine vises and quick change fixturing components, Orange Vise also performs a significant amount of contract manufacturing. The disc brushes he utilizes are from the NamPower line developed by Brush Research Manufacturing. Composed of flexible abrasive nylon filaments bonded to a fiber reinforced thermoplastic base, the abrasive disc brushes contain a unique combination of both ceramic and silicon carbide abrasive. The abrasive filaments work like flexible files, conforming to part contours, wiping and filing across part edges and surfaces of non-ferrous, cast iron, mild steel and ductile iron, stainless and alloy steels, titanium and high nickel alloys. “For us, there really isn’t another solution, because the alternative is to have a worker use a file or a handheld abrasive pad, and the part is not going to have the finish you get with the abrasive nylon brushes,” says Sun. Edge finishing, often without chamfer tools Finishing sharp edges between two faces of a part, as well as deburring bits of metal or imperfections caused by the cutting action of the tools, can be accomplished with a variety of techniques. Hand finishing is an option, as are options such as tumbling. Chamfering tools are also frequently used to provide a transitional edge at 90 degree angles, as well as for deburring. For some contract manufacturers, however, eliminating the chamfering step can prove valuable. “I run the abrasive nylon brushes over any fairly flat part I have going in the mill,” says Ken Spaulding of Zodiac Engineering, a contract manufacturer in California with a background in aerospace parts as well as mold making. “I don’t want to use a chamfer tool for edge breaking or deburring if it’s not necessary.” The majority of the machining work Spaulding currently focuses on includes pocket knives as well as cycling components for BMX, road and mountain bikes. Spaulding sells products of his own design, along with contract manufacturing. Spaulding uses the NamPower abrasive discs on his CNC and manual milling equipment for light deburring as well as surface finishing of various types of metals and alloys. For the pocketknives, this includes stainless steel for the blades and titanium and zirconium for the frames and handles; and 6061 aluminum for the bike stems and 7000 series aluminum for the sprockets. “With the brushes, I get a very predictable and consistent edge break and surface finish,” says Spaulding. “I can do it inline and it is a lot more predictable and reliable than breaking edges by hand.” For the cycle sprockets he produces, for example, Spaulding runs the brushes over the teeth in a single pass on each side of the part. “The brushes deburr pretty much every side of the tooth, so I don’t have to run a chamfer tool around the edges. Also, tumbling doesn’t really get inside the teeth, like the brush does,” explains Spaulding. Even when chamfer tools are specified, the edges may still require deburring. “Chamfering tools are just half of the puzzle,” says Sun of Orange Vise. “The other half is some sort of abrasive method, such as tumbling. However, tumbling can be impractical for larger parts or anything that needs to remain dimensionally unaffected.” Instead, Sun finds abrasive nylon brushes “complementary” to 45 degree chamfering tools. This extends to chamfered holes. “Often chamfers leave burrs on the top and the inside edges of drilled holes, so we use the NamPower brushes because they are flexible enough to remove any burrs from the top edge, while going into the hole enough to deburr the lower edge,” says Sun. Minor edge breaking is another potential use for the abrasive nylon brush. Although most manufacturers specify the degree of edge finishing, there can be gray areas where a customer may not want a sharp 90 degree edge but does not specify chamfering. In cases like this, Orange Vise may slightly round off the edges and corners with an abrasive nylon brush. The rounding can be minimal, if necessary, so it is not visible to the naked eye. Surface Finishing without Face Milling In addition to edge finishing, the abrasive nylon brush has application for surface finishing. In some cases, this can replace the use more aggressive face mills, flycutters or grinders. Sun describes the finish as “almost like a milled finish, with a consistent swirl pattern in one direction.” “The surface finish was good enough that we were actually blending it with our ground finishes on our vices,” says Sun. “With large surfaces that required multiple passes, there were no visible blends.  The whole thing looked like it was

Miniaturization of Rupture Disks Forces Industry Back to Drawing Board Miniaturization of Rupture Disks Forces Industry Back to Drawing Board Miniaturized rupture disks from 1/8” to 1” deliver protection against overpressurization at low, medium and high set burst pressures For more than 85 years, the rupture disk has served as an effective passive safety mechanism to protect against overpressure or potentially damaging vacuum conditions in oil and gas storage tanks and other enclosed vessels. However, as these pressure relief devices become increasingly miniaturized to sizes as small as 1/8” to meet the demands of a new generation of smaller, lighter applications, the industry is running squarely into design and raw material challenges that often require reengineering the product itself. Fortunately, leading rupture disk manufacturers have embraced this challenge with novel structures and design elements that have led to a new category of miniaturized options from 1/8” to 1” at all ranges of pressure including low (15-1000 psi), medium (350-16,000 psi) and high (1,500-70,000 psi). The beneficiaries are expected to be equipment manufacturers and design engineers currently developing the next generation of oil, gas, and petrochemical processing systems. The Evolution of Rupture Disks To understand the challenge requires an understanding of the origins of rupture disk technology. When it comes to pressure relief devices, the two most common are safety valves (reclosing) and rupture disks, also known as bursting discs (non-reclosing). Rupture disks are designed to fail within milliseconds when a predetermined differential pressure, either positive or vacuum, is achieved. The device has a one-time-use membrane usually made out of various metals, but also exotic alloys and graphite. In many applications the superior leak tightness and flow characteristics of a rupture disk are preferred over safety valves, which are known to leak. In fact, it is a common industry practice to install a rupture disk on the inlet side of a safety valve to economically protect against corrosion and provide the required leak tightness. In another potential use unrelated to pressure relief, rupture disks can be designed to activate as one-time fast acting valves or triggering devices to initiate a sequence of actions with high reliability and speed. Transition to Miniature For decades, rupture disks have been used in petrochemical, chemical and oil field applications. In these applications, rupture disk sizes ranged from 1”- 6”, with larger sizes up to 60” for the largest piping configurations. To install the product, the rupture disc is placed in a holding device, called a safety head, and installed between flanged pipe ends. However, as equipment manufacturers strive to make their products smaller and lighter, the rupture disk industry has been challenged to deliver miniaturized options well under 1” in diameter. Due to a delicate balancing act between the shrinking diameters, a complicated choice between two rupture disk design philosophies, the limitations of the specific raw materials utilized for the membrane, and the variations required to meet the requirements for low, mid and high burst pressures have forced rupture disk manufacturers to the drawing board. Competing Designs: Forward-Acting vs. Reverse Buckling The first major decision when selecting any rupture disk of any size is the choice between forward-acting and reverse buckling technologies. In the traditional forward-acting design, the loads are applied to the concave side of the disk. The thickness of the raw material employed and the diameter of the fitting in which it is mounted determine performance. However, with this approach the rupture disk is prone to metal fatigue caused by aggressive cycling and operating conditions that can limit its operational life. Traditional rupture disk technology is additionally limited to applications having an operating to burst pressure ratio of 75% or less to avoid fatigue effects leading to potential unwanted activation. Exacerbating the issue, forward-acting miniaturized disks with low set pressures require the use of tissue paper thin raw material that is fragile and prone to leakage when assembled. This has caused a somewhat negative view of this type of disk even though it is still utilized in many static pressure applications and suffices for certain high pressure applications. In a reverse buckling design, on the other hand, the dome is inverted toward the source of the load. Burst pressure is accurately controlled by a combination of material properties and the shape of the domed structure. By loading the reverse buckling disk in compression it is able to resist operating pressures up to 100% of minimum burst pressure even under pressure cycling or pulsating conditions.  The result is greater longevity, accuracy and reliability over time. The Miniaturization Challenge However, miniaturization of reverse buckling technology presents its own unique challenges, says Geof Brazier, Managing Director, BS&B Safety Systems, Custom Engineered Products Division. BS&B Safety Systems invented the first rupture disk device in 1931. The company later pioneered reverse buckling technology and, more recently, the application of that approach to miniaturized disks as small as 1/8” at all ranges of pressure. “As burst diameters decrease it becomes increasingly difficult to design a reverse buckling dome that will reliably collapse through such small orifice sizes,” says Brazier. “In many ways it can be like trying to fit a camel through the eye of a needle.” To resolve this issue, BS&B has created novel structures that control the reversal of the rupture disk to always collapse in a predictable manner. This includes, for example, a hybrid shape that combines reverse buckling and forward bulging characteristics that are pre-collapsed. In this type of design, a line of weakness is typically placed into the rupture disk structure to define a specific opening flow area when the reverse type disk activates. Small nominal size rupture disks can also be very sensitive to the detailed characteristics of the orifice through which they burst, causing normal variations in holder support machined part dimensions to have an unwanted impact on burst pressure accuracy. “With small size pressure relief devices, the influence of every feature of both the rupture disk and its holder is amplified,” explains Brazier. For miniaturized products ¼” and up certified for high burst pressures up to 70,000

Loss Prevention Devices for High-End, Interactive Consumer Electronics Loss Prevention Devices for High-End, Interactive Consumer Electronics New options prevent theft of high end electronic devices while allowing for maximum customer interactivity – without the mess and clutter For retailers of high end consumer electronics such as smartphones, tablets, e-readers, drones, digital cameras, and fitness watches, the customer’s retail experience can be just as important as loss prevention. Often the look, feel, and performance of the product on display in store, including the ability to interact and fully experience features such as menus and apps, can be crucial in a customer’s purchasing decision. Yet retailers cannot let expensive merchandise “walk out the door” due to shoplifting or employee theft. According to the 2016 National Retail Security Survey (NRSS), retailer inventory shrinkage accounted for 1.38 percent of sales – up $1.2 billion from the previous year. In addition, 47 percent of retailers surveyed reported increases in overall inventory shrinkage. Electronic loss prevention devices, which typically involve an alarm console, sensors, and related accessories, are the ideal way to display this type of merchandise. Now as a proliferation of new consumer electronics products hits the market and retailers face competitive pressure to reduce costs and staffing, a greater array of standard and custom options is further improving this category’s appeal in the industry. “Customers need to interact with our latest smartphones to see what has changed and how the devices perform,” says Bill Jones, an AT&T regional Director of Asset Protection. “But it is a balancing act between customer-product interaction and theft deterrence.” According to Jones, who evaluates loss prevention system cost and effectiveness, in today’s competitive retail environment, how a product looks and feels when displayed can affect a retailer’s bottom line just as much as theft prevention. “We want the focus to be on the product, rather than on the power and security cords,” says Jones. “Some of the theft deterrent options on the market create quite a bit of clutter and look outdated. They do not match the cutting edge products or brands we promote.” Improving Product Presentation Any electronic loss prevention device – whether alarm console, sensor, pedestal stand, grippers, tethering or charging cable – should not overshadow the product itself or be cumbersome or difficult to maintain by employees. To meet this need, innovators in the industry offer a variety of loss prevention devices that secure electronic products without the mess and clutter. A growing number of retailers, for instance, are turning to electronic merchandise display security systems like the Vantage II by Se-Kure Controls, a Franklin Park, Illinois-based manufacturer of retail product security devices. While most systems require separate wires for security and charging the electronic device it protects, this system utilizes a single wire to provide both security and power. “One of the things that drew us to our display security system is how nice, clean and modern it looked to have the one cord,” says Kevin Lasky, project manager for Arch Telecom, a wireless retailer with 140 locations in 13 states. “There is no separate cable running up the side of the pedestal or coming out of the display to charge the phone. That was important to us.” The system also offers an option for dual sensors to prevent theft of the device, as well as detachable accessories of value such as lithium batteries or a removable camera lens for digital cameras. To facilitate customer-product interaction in stores, retailers can pair each smartphone with a retractable cord so it can be pulled off its pedestal and easily viewed at a distance several feet away. When the shopper returns the phone to the pedestal, the cord retracts and a magnet enables ideal product positioning. The industry has also managed to further reduce clutter in retail showrooms by streamlining how electronic devices are powered. Some alarm consoles, such as those from Se-Kure Controls, have been designed to provide continuous power and security to multiple 5V devices such as tablets, smartphones, and e-readers through a single cable via a series of USB ports. Up to twelve devices can be charged from one alarm console. This eliminates the need to plug in a bulky power adapter for each device into a power strip mounted below the display. AT&T’s Jones says he is also impressed with the simplified, cleaner look of the single cord approach. It also simplifies removal of electronic products to a more secure location each evening to prevent “smash and grab” robbery attempts. “At the end of each day, we put all our devices in an inventory room, and then each morning we put them back on the display counters,” he adds. “Having just one cord helps us close down and set back up faster.” According to Jones, Se-Kure Controls’ systems are also very sturdy and durable. He estimates that not having to repair or replace items such as the alarm box or power/security cords often can lead to significant savings annually. “In an organization as big as ours, it can add up to millions of dollars over time,” says Jones. Because retail settings vary widely in their display requirements, loss prevention devices frequently need to be customized. Some manufacturers of loss prevention devices have the capability and resources to make critical adjustments. This can include accommodating devices to the number and size of items requiring protection, along with features such as pedestal height, security cord length, size, color, and retractability, as well as alarm, power, and sensor options. With in-house metal fabrication and plastic injection molding capabilities, as well as electronic manufacturing expertise, Se-Kure Controls is also able to adapt to inevitable changes in the types and styles of consumer electronics on the market. With the global market for wearable electronics projected to surpass $30 billion by 2020, the need to adapt loss prevention devices to protect new products while allowing for continued customer interaction will only increase. “Our retail stores are always experimenting with what we carry,” says Jones. “As technology continues to change,

Preserving the History of Historical Buildings and Windows Preserving the History of Historical Buildings and Windows Unique “soundproof” windows dramatically reduce outside noise and increase energy efficiency with a hands-off approach to the original windows “Windows are one of the most important and integral character-defining features of historic buildings,” states the D.C. Historic Preservation Review Board in its publication Window Repair and Replacement Preservation and Design Guidelines. “They provide a sense of scale, craftsmanship, proportion and architectural styling.” As such, the primary objective of historic commissions and review boards, not to mention federal and local preservation statutes, is to ensure the existing windows remain intact whenever possible. For this reason, repair is often recommended over replacement with more modern, double-paned windows that can quickly ruin a building’s character and charm. Repairing aging historic windows, however, has limits. Although glass can be replaced and weather stripping installed, single pane windows do not provide the “air gap” that is the key to the noise reduction and thermal efficiency of the double-pane approach. Fortunately, an alternative approach preserves the historic and embraces the modern while not altering the original window. Instead, a unique “second window” is installed on the interior that can be opened or closed like the original. Unlike storm windows or glazed panels, these “soundproof” windows maximize both exterior noise reduction and thermal efficiency, and are found in historical districts and sites nationwide. Maintaining Historic Character Owners of historic properties have good reason to upgrade their windows. While beautiful, the traditional single pane windows found in historical properties are particularly prone to external noise intrusion. In addition, the design offers poor thermal insulation properties. Lawrence Posner sought to preserve the historic 10-foot double hung windows on four of his Victorian cottages, which were certified by the National Park Service. Yet these picturesque cottages, including one he was living in, were located close to the blaring horns of a railroad. “There’s a double set of train tracks between the cottages and the river, and every few feet the trains would blow their horns,” says Posner. “It was deafening. I had to wear earplugs to sleep. There’s nothing like historic double hung windows for aesthetics, but the windows let the racket right in.” The beauty of Posner’s cottages and their location, Fort Conde Village, a Mobile, Alabama community of unique Victorian properties meticulously restored to their original design, contrasted sharply with the racket of the railroad. Fort Conde Village, located next to Fort Conde, a pre Revolutionary War fort, is known for its historic details, from the buildings to the gas lamps that light its cobblestone streets. For Posner, replacing the historic windows of his cottages was not really an option because he did not want to compromise the aesthetics, and getting approval to do so from the National Park Service would be difficult, if not impossible. Posner turned to Soundproof Windows, Inc, a company with expertise engineering windows for some of the most noise sensitive environments in the world, such as recording studios. The company has created a second, inner soundproofing window not visible from outside the building that is ideal for historic buildings. The product is custom designed specifically to match – and function – like the original window. It is also designed to be installed quickly. The inner window essentially reduces noise from entering on three fronts: the type of materials used to make the pane, the ideal air space between original window and insert, and finally improved, long-lasting seals. The combination can reduce external noise by up to 95%. The first noise barrier is laminated glass, which dampens sound vibration much like a finger on a wine glass stops it from ringing when struck. An inner PVB layer of plastic further dampens sound vibrations. Air space of 2-4 inches between the existing window and the Soundproof Window also significantly improves noise reduction because it isolates the window frame from external sound vibrations. Finally, the company places spring-loaded seals in the second window frame. This puts a constant squeeze on the glass panels, which prevents sound leaks and helps to stop noise from vibrating through the glass. When choosing such soundproofed windows for a historic renovation project, the most objective measure of sound reduction is the window’s Sound Transmission Class (STC) rating. In this rating system, the higher the number the more noise is stopped. A typical rating for standard windows is 26 to 28, for example. The acoustic soundproof windows, by comparison, earn a 48 to 54 STC rating. “The soundproof windows saved my life,” says Posner. “They would save anybody’s life if they had to deal with that sort of train racket and noise on a daily and nightly basis.” Soundproofing the windows of historic buildings can also significantly reduce energy costs. Adding the inner window provides an additional layer of insulation with better insulation values than the best low-e, argon gas filled double paned window. This can reduce heat loss by 77% or more for single paned windows. The added insulation stops unwanted air infiltration around and through window seals, and can reduce the heating-cooling portion of energy bills by 15-30%. According to Posner, while he purchased the windows primarily for soundproofing, they also have value in terms of lowering heating and cooling costs. “The windows have helped to prevent cold drafts from entering and improve insulation and energy efficiency,” he says. “That’s important to long term comfort as well.” With an upgrade to the latest soundproof windows, renovators and owners no longer have to settle. Now they can preserve the historic character of properties while achieving modern comfort. For more information, contact Soundproof Windows, Inc. at 4673 Aircenter Circle, Reno, NV 89502; call 1-877-438-7843; email sales@soundproofwindows.com; or visit http://www.soundproofwindows.com

Quiet, Dignified Lifts to the Second Floor for Schools and Universities Quiet, Dignified Lifts to the Second Floor for Schools and Universities Compact wheelchair lifts allow mezzanine and second floor access for those with mobility challenges One challenge for K-12 and university facility managers tasked to meet the Americans with Disabilities Act (ADA) has been offering full access to elevated areas on campus. These areas can range from stages and raised platforms to theater, auditorium, library, administrative offices and student centers with mezzanines or second floors not served by a traditional elevator. In such cases, ramps and one-floor elevators often require too much space to be feasible, particularly in older buildings. Although wheelchair lifts are available to assist those with mobility issues, most are limited to a 60-inch or less maximum vertical lift, which is sufficient for a stage, but not a second floor. For lift platforms that are capable of reaching higher, many are poorly designed and disruptive, too tightly enclosed for those uncomfortable in small spaces, and require demolition of floors or walls to hide internal lift machinery. Now, however, industry advances promise quieter, ADA compliant wheelchair lifts that offer extended vertical reach as well as dignity to their users with minimal installation requirements. Access Alternatives If there is enough floor space, building a ramp is probably the simplest solution for providing access to those using wheelchairs, walkers, crutches, canes or other assistive devices. However, ramps typically need to be one foot long for every inch of vertical gain, so a 48-inch high stage requires a 48-foot long ramp. This is impractical in space restricted older buildings, especially for mezzanine and second floor access. Besides being unsightly, ramps can also be difficult to navigate due to the incline. Installing a traditional elevator is another option, but can be costly and usually requires both overhead clearance for a machine room and demolition to flooring to put machinery below. For these reasons, a dedicated elevator that only goes up one floor is generally not cost-effective or feasible unless access to multiple floors is required. Although extended rise wheelchair lifts are a good alternative, traditional devices have a number of drawbacks. Most require up to 6 inches of machinery underneath so require demolition of the floor to create the space to hide machinery, or placing it in a raised platform above the floor with a flip down ramp, or sometimes both. Because some lift machine cabinets stand on the side of the unit and may even have sheet metal all the way around, this also limits visibility in and out of the unit, which can be a problem for anyone claustrophobic or educators who must monitor students for safety. Typical lifts operating with screw or worm gear drives can also be very noisy and disruptive. The devices can generate a loud, grinding sound similar to a high-speed drill or trash compactor. This not only puts an unwelcome focus on those using the lift, but also detracts from the educational environment. Fortunately, school facility managers are finding that design improvements in extended rise wheelchair lifts are making ADA access safer, easier, and more inclusive, with less intrusive renovation to existing structures. Unlike excessively loud wheelchair lifts utilizing screw or worm gear drives, some advanced lifts such as the Clarity 16E by Ascension, a wheelchair lift manufacturer based in Tucson, AZ, use an electro hydraulic drivetrain and vibration-isolating supports, which significantly reduce noise to take the spotlight off of those using the lifts and preserve educational decorum. When rising, for instance, the unit is about as loud as normal conversation (62dB @ 3 feet), and it is virtually silent when descending (< 2dB @ 3 feet). Because the unit, a fully enclosed vertical wheelchair lift that can reach heights up to 168-inches, mounts directly on the floor this means that no equipment pit under the lift and no floor demolition is required, which is particularly important for historic structures or venues. Since the lift mounts directly on the floor with a very slim profile platform only 1/2-inch thick, the person in the wheelchair or using an assistive device also safely and easily enters at floor level without requiring a cumbersome fold-out entry ramp. For tight renovation spaces, a lift with a narrow footprint can also mean the difference between a painless installation and major wall demolition to squeeze in the new lift. In this regard, the lift’s narrow 48-inch wide footprint allows the device to fit into existing structures without tearing down walls to make space. This is possible because the machine cabinet mounts up against the wall, not the sides, making it at least 6 to 8 inches narrower than traditional lifts. Because no side tower is required, the drive system attaches directly to the landing face, and the enclosure uses transparent panels which leave three sides clear for better sight lines in an out of the lift as well. This creates a more open, less enclosed feeling for those using the lift and enables better visual monitoring of students for safety. Another safety feature included with the system is an ADA-compliant hands-free phone with auto dialer for two-way communication from the platform. Beyond safe, quiet ADA compliance, facility managers will want to know that the wheelchair lift they depend on is built to last with minimal maintenance. While the industry typically offers a 1 to 3 year warranty on lift drivetrains, some advanced lifts now carry a standard drive train warranty of 20 years with 5 years on all other parts, which ensures better equipment longevity. As educators look to be ADA compliant and meet the needs of all of their students, extended rise wheelchair lifts will help them to safely meet access requirements in a dignified manner for a wider range of structures and facilities. For more info, call 800-459-0400; email article@ascension-lift.com; visit www. ascension-lift.com; or write to Ascension at 3526 E. Fort Lowell Rd., Tucson, AZ 85716.

Corrosion Resistant Plastic Cooling Towers Cut Costs for Sintering Operations Corrosion Resistant Plastic Cooling Towers Cut Costs for Sintering Operations For metalworking operations using extreme heats, engineered plastic cooling towers provide effective cooling without corroding, outlasting traditional alternatives When it comes to process cooling, few industries rely on the application of heat as much as the sintering process in powder metal manufacturing. With temperatures in the “high-heat” section of a sintering furnace reaching several thousand degrees Fahrenheit, the parts must be dramatically cooled before they can be handled safely by operators. Sintering is a process by which metal particles are chemically bonded and formed by heat and pressure without reaching the point of total liquefaction. To accomplish this, powdered metal and alloy mixtures are compacted into near-net shapes, typically using a high pressure press. The compacted material must then be placed in a sintering furnace to improve the bonds and harden the material to the desired final specifications. To expedite the temperature reduction process, cooling towers are commonly used to circulate water through a jacket that cools the air surrounding the part. Unfortunately for sintering, metalworking and other industrial processes, the most common type of cooling towers are constructed of galvanized steel and so are susceptible to corrosion and rust problems that can increasingly require ongoing maintenance, often causing expensive process downtime along with repair costs. Structure Maintenance Solutions, Drawbacks For Phoenix Sintered Metals, LLC, a powdered metal part manufacturer, a galvanized cooling tower the company inherited when it purchased the facility was so corroded it was losing water (and expensive water treatment chemical) at an alarming rate. In addition, patching was only slowing, but not preventing, the issue. “We were losing a lot of water out the bottom of the cooling tower on a daily basis because of the leaks,” explains Josh Crawford, Maintenance Supervisor at Phoenix Sintered Metals. Unfortunately, for aging galvanized cooling towers, this scenario is not unique. Metal cooling towers are under constant attack by salt air or the caustic atmosphere of many industrial sites. Minerals in hard water as well as its pH level can also contribute to corrosion. To combat the slow, inevitable deterioration, plant personnel are often tasked with patching panels and holes. This work only increases before the cooling tower is eventually replaced. Even with diligent maintenance practices and cooling water chemistries, galvanized cooling towers typically must be replaced every 7-12 years. “We were spending a lot of time trying to patch cracks in the floors and we were able to contain it a little bit, but never able to completely stop it. As time went on, the cooling tower continued to rust and the problem became worse,” adds Crawford. The cooling tower, having been relocated from a shuttered, second location prior to the acquisition of the business, was also oversized for the current operation by about 60%. While this did not impact the unit’s cooling capability, an oversized unit adds to operating costs in terms of electricity to operate fans and pumps, as well as water replacement and specialized water chemistries. Eager for a more permanent solution, Crawford contacted ProChemTech, a company that provides cooling water chemistry, systems design and engineering solutions, to inspect and evaluate the system. “The previous ownership used that tower for quite a few years,” says Bill Foringer, plant manager at ProChemTech. “Initially, [Phoenix Sintered] considered refurbishing it, but that isn’t cost effective when you need new fan, motor, base and pan – it can get quite expensive. So, at that point we started looking at new cooling towers.” Engineered Plastic Cooling Towers When asked to make a recommendation, ProChemTech suggested a HDPE (high-density polyethylene) plastic cooling tower from Delta Cooling Towers (www.deltacooling.com), one of the industry’s leading manufacturers of engineered plastic cooling towers since 1971. Delta Cooling Towers offers a full line of factory assembled and modular plastic cooling towers in capacities up to 2,500 tons for a wide range of metalworking applications. Made from corrosion-proof engineered plastic, the low maintenance, seamless “one-piece” shell design has no joints, seams, panels, gaskets, bolts, fasteners or caulking like conventional towers. “What drew our attention right away is that we wouldn’t have to worry about the rusting of the shell,” says Crawford. “Granted, had we purchased a new, galvanized tower it wouldn’t require much upkeep at first, but eventually it would get to that point where we would have those same issues.” The design selected by ProChemTech was the T125i model. The Paragon Induced Draft Tower features a counter flowing tower design available in single module capacities from 55 to 250 cooling tons. Crawford was also impressed by the cost and length of warranty associated with plastic cooling towers. Because HDPE towers are unaffected by corrosives, they require little maintenance and provide a much longer service life. Delta cooling towers, for example, all have a 20-year warranty. “The cooling tower was a little cheaper than galvanized and had a better warranty as well,” says Crawford. According to Crawford, the unit was installed in July, 2016 by a local contractor recommended by ProChemTech and has been working well since. For more information, contact Delta Cooling Towers, Inc., Phone (800) 289.3358; Fax 973.586.2243; E-mail: sales@deltacooling.com; or visit the web site: www.deltacooling.com

Meeting the Communications Challenges of Harsh Water/Wastewater Treatment Plant Environments Meeting the Communications Challenges of Harsh Water/Wastewater Treatment Plant Environments Using ruggedized fiber optic cable, connectors and enclosures can ensure that network communications run reliably at high speed – far into the future. Every year, serious accidents occur at water and wastewater treatment facilities around the world. Often these calamities are attributable to a breakdown in the communications systems that monitor and control the flow of critical plant processes through various treatment stages and vessels. Events such as overflows caused by motors or valves failing to actuate, for example, can result in flooding that spills potentially millions of gallons of untreated sewage into waterways and communities, threatening the ecosystem as well as the health of residents. Most of the functions of treatment plants are monitored and controlled by cable-based communications systems, and because they are exposed to very harsh chemicals and elements, it is vital to plant safety that these systems – including cables, RTUs, enclosures and so forth – are operating with optimal speed and reliability. Even when communications systems are operating efficiently, serious problems can result. For example, outdated communications networks based on copper cabling can slow treatment plant throughput, resulting in insufficient capacity to support a community’s sewage disposal requirements. Outmoded communication networks can also result in exorbitant plant and network maintenance costs due to frequent service, as well as security and environmental compliance problems. For all of those reasons, today’s efficient wastewater treatment plants are basing their communications network infrastructures on ultra-reliable, high-speed fiber optic cabling coupled with connection and control devices that are designed to withstand the harsh environments within those plants. This approach not only protects against environmental accidents, but can also ensure optimum plant throughput, security and compliance. Challenging Operational Environments As with other networks that monitor and control switches, motors, valves and other devices throughout a plant, the need for speed is growing exponentially within many wastewater treatment plants. In Elk Grove, California, the Sacramento Regional County Sanitation District (Regional San) is constructing the EchoWater Project at the Sacramento Regional Wastewater Treatment Plant (SRWTP) at a cost approaching $2 billion. This project will allow the SRWTP to meet discharge requirements set by the Central Valley Regional Water Quality Control Board and State Water Resources Control Board in 2010, and in subsequent amendments. When completed in 2023, the EchoWater Project will improve the quality of water discharged into the Sacramento River, increase opportunities for water recycling, and ensure safe and reliable wastewater treatment for the more than 1.4 million residents in the Sacramento region. Ronald Kwok, Associate Electrical Engineer at the facility, says that a high-speed, fiber-optic based communication network is essential to meeting increasing data transfer requirements for monitoring and controlling wastewater treatment plant operations. “Our communications network is currently running at 100 megabits per second,” he says. “It will soon be at the 1GB (1,000 megabits) per second rate. Only a high-speed fiber network can accomplish that.” While upgrading to a high-speed fiber system is a top priority for many wastewater treatment plants, selecting the appropriate type of cable, connectors and enclosures utilized in these harsh environments is critical. In municipal treatment plants, such as Sacramento’s, communications infrastructures are exposed to harsh chemicals such as chlorine, bromine, sulfur dioxide and methane. Networks installed in industrial treatment plants could be exposed to a much wider array of harsh elements, including caustic acids, sulfates and salts. Kwok, who has been with Regional San for almost 20 years, says it is essential to wastewater treatment plant communication system performance and reliability that fiber optic cable and related components have the durability to survive in such harsh environments. A Long-term Solution The main physical attributes that are usually required of cable in this environment are chemical resistance, impact resistance, and the ability to bend without damaging the cable jacket or fiber strands inside. Tight-buffered, tight-bound cable has many advantages over loose tube or ribbon-type cable, which is still in use at some wastewater treatment plants. To begin with, this type of cable offers fluoropolymer jacketing built to withstand long-term, severe chemical environments, including the caustic vapors present in most water treatment plants. These cables offer excellent impact and moisture resistance over loose-tube gel-filled type cable constructions. They are designed for both indoor and outdoor use, and are capable of long-term survival in humid and wet environments. In wastewater treatment plants this durability is vital to maintaining PLC, RTU and SCADA signal integrity as well as overall network-wide transmission reliability for optimal plant performance. Tight-buffered cables are also ideal for security camera applications to provide high definition video imaging to protect wastewater treatment plants against intrusions, equipment failures, or other threats. These types of cables are expected to provide many decades of reliable service plus significantly less downtime and reduced maintenance costs. Ruggedized Fiber Advantages There are many different types of tight-buffered, tightbound fiber optic cable available, although Optical Cable Corporation’s (OCC) (www.occfiber.com) BX Series breakout and DX Series distribution cable are the versions most commonly used in wastewater treatment plant applications. When it comes to harsh conditions ruggedized tight-buffered fiber cables are more appropriate for applications with harsh environments, such as water and wastewater treatment plants. These cables offer exceptional physical characteristics, including bend, crush, impact, and chemical resistance across a broad thermal operating range. Ruggedized tight-buffered cables are also capable of reducing attenuation loss, speeding installation, and maximizing “up time.” OCC pioneered the design and production of tight-buffered cables for the most demanding military field applications. The company currently manufactures a broad range of fiber optic cables for high bandwidth transmission of data, video, and audio communications, including cables for the most demanding commercial and industrial environments. Among the most popular cables for harsh environments are the 12-strand BX Series breakout cable and the D Series and a variety of BX Series armored distribution cables. Protected Connections and Enclosures Wastewater treatment plants can also benefit from the installation of cable connectors that are

The High Cost of Exposing Ag Workers to Chemicals at Point of Use The High Cost of Exposing Ag Workers to Chemicals at Point of Use The tip-and-pour method, as well as poorly designed pumps, can expose workers to injury and companies to significant financial losses Every day handlers and applicators transfer potentially hazardous chemicals and concentrates such as pesticides, herbicides, insecticides, fungicides, and liquid fertilizers from large drums into smaller containers or mixing tanks. This transfer process can have serious consequences if manual “tip-and-pour” techniques or poorly designed pumps are used. Whether the chemicals are toxic, corrosive, or flammable, the danger of accidental contact can pose a severe hazard to workers. In fact, each year 1,800-3,000 preventable occupational incidents involving pesticide exposure are reported. Keeping workers safe is not just a best management practice – it is the law. The federal Worker Protection Standard (WPS) was revised in 2015 and now provides a greater focus on reducing pesticide exposures. A closed system of transferring chemicals reduces unnecessary exposures by providing controlled delivery of chemical products without fear of worker exposure, over-pouring, spilling, or releasing vapors. Many of the revisions became effective this January. “When handling pesticides, toxicity and corrosiveness are the main dangers, but even organic pesticides can be harmful if there is exposure,” says Kerry Richards, Ph.D., President Elect of the American Association of Pesticide Safety Educators and former Director of Penn State’s Pesticide Safety Education Program. “No matter what their toxicity level, all chemicals, even those that are organic are a particular contact exposure risk if they are corrosive.” In addition to the potential for injury, there can also be serious financial ramifications for the grower or ag product manufacturing facility if pesticides or liquid chemicals spill. “Beyond workers compensation issues related to exposure, there can be other huge potential liabilities: Environmental Protection Agency (federal) or state regulatory fines, as well as clean-up or remediation costs,” says Richards. “This is particularly true if a pesticide gets into a water source, kills fish, or contaminates drinking water.” Spiraling Costs of Lost Containment Richards, who works with the National Pesticide Safety Education Center, has seen and heard many examples of worker and environmental exposure from pesticides in over 30 years of pesticide safety education experience. “Exposure risk is highest for those loading chemicals into mix tanks because it is more concentrated and hazardous before diluted with water,” she says. “Any time you lose containment of the chemical, such as a spill, the risks can be serious and spiral out of control.” Corrosive chemicals, for example, can severely burn skin or eyes, and many chemical pesticides are toxic when touched or inhaled. “Some organic herbicides are so highly acidic that they essentially burn the waxy cuticle off the above ground parts of plants, killing them,” says Richards. “If you splash it in your eye or on your skin, it can burn in the same way and cause significant damage.” Some chemicals are flammable as well, and if not properly handled and contained, can be ignited by sparking from nearby motors or mechanical equipment. The danger of a fire spreading can be serious both in the field and at ag product manufacturing facilities. In addition to the cost of cleanup or treating injuries, substantial indirect costs can also be incurred. These include supervisors’ time to document the incident and respond to any added government inspection or scrutiny, as well as the potential for slowed grower production or even a temporary shutdown at ag manufacturing plants. “The direct and indirect costs of a pesticide spill or injury can be substantial, not the least of which is the loss of wasted chemicals,” says Richards. “Pesticides, particularly newer concentrated formulations, are very expensive so spilling a few ounces could cost you several hundred dollars in lost product during a single transfer.” Chemical Transfer Techniques Traditional practices of transferring liquid chemicals suffer from a number of drawbacks. Manual techniques, such as the tip-and-pour method, are still common today. Tipping heavy barrels or even 2.5 gallon containers, however, can lead to a loss of control and over pouring. “When manually transferring chemicals from bulk containers, it is very difficult to control heavy drums,” cautions Richards. “I’d advise against it because of the significantly increased risk of exposure or a spill, and the added potential of a back injury or muscle strain.” Although a number of pump types exist for chemical transfer (rotary, siphon, lever-action, piston and electric), most are not engineered as a sealed, contained system. In addition, these pumps can have seals that leak, are known to wear out quickly, and can be difficult to operate, making precise volume control and dispensing difficult. In contrast, closed systems can dramatically improve the safety and efficiency of chemical transfer. California’s Department of Pesticide Regulation, in fact, requires a closed system for mixing and loading for certain pesticides so handlers are not directly exposed to the pesticide. “The availability of new technology that creates a closed or sealed system is ideal for handling pesticides or other dangerous chemicals, and should become a best management practice,” suggests Richards. “With such devices, for example GoatThroat Pumps, pesticide handlers can maintain a controlled containment from one vessel to another and significantly reduce any potential for exposure or spill.” A sealed system delivers liquids to an intermediate measuring device and is useful for low toxicity liquids. A closed system moves the material from point A to point B through hoses using dry-break fittings on the connection points. This prevents leaking and exposure to the handler which helps guarantee safety. Liquids are transferred from the source container, into the measuring system, and then to the mix tank. Small, versatile, hand-operated pressure pumps, such as those manufactured by GoatThroat Pumps, are engineered to work as a system which can be either closed or sealed. The pumps can be used for the safe transfer of over 1400 industrial chemicals, including the most aggressive pesticides. These pumps function essentially like a beer tap. The operator

A Simpler, Less Intrusive Buying Experience: Loss Prevention Devices for High End Clothes and Accessories A Simpler, Less Intrusive Buying Experience: Loss Prevention Devices for High End Clothes and Accessories New options prevent theft of designer apparel and accessories, while enabling hands-on interaction with less clutter For retailers of high-end apparel and accessories such as purses, clutches, belts, furs, designer gowns, leather jackets, shoes, watches and jewelry, the customer’s retail experience can be just as important as loss prevention. Often the look and feel of the product on display in store, including the customer’s ability to consider how the item complements one’s personal style, can be crucial in the purchasing decision. While intrusive loss prevention devices cannot be a barrier to consumers during the sales process, retailers cannot let expensive merchandise “walk out the door” due to shoplifting or employee theft. According to the 2016 National Retail Security Survey (NRSS), retailer inventory shrinkage accounted for 1.38 percent of sales – up $1.2 billion from the previous year. In addition, 47 percent of retailers surveyed reported increases in overall inventory shrinkage. When some high-end items like designer handbags can cost $2,000 each or more, protecting against “grab and run” theft is critical. A single incident that can take only a few minutes can cost a retailer tens of thousands of dollars as an entire rack of merchandise is swept into a bag and out of the store. The ideal way to display such designer merchandise is with innovative mechanical or electronic loss prevention devices, which may involve cords, sensors, an alarm console and related equipment. With online competition crimping margins and reducing brick-and-mortar retail staffing today, using effective theft deterrent devices is even more important. Now a greater array of options is allowing retailers to prevent theft and showcase merchandise more naturally with less intrusion. Enhancing Product Presentation and Security Any loss prevention device – whether a mechanical tether, alarm console or sensor – should not overshadow the product, or be cumbersome or difficult to maintain by employees. To meet this need, innovators in the industry offer a variety of loss prevention devices that secure designer products with minimal visual clutter or intrusiveness. In the case of a haute couture handbag, for instance, it is essential for shopper to see for herself how it feels on the shoulder, how it rests against the hip, as well as how it opens and how much storage it offers. Yet protecting against grab and run theft is equally important and must not compromise the in-store purchase experience. Against such theft, companies like Se-Kure Controls, a Franklin Park, Illinois-based manufacturer of retail product security devices, offer small, retractable, lockable cords that allow customers to examine handbags up close. When the shopper returns the handbag, the cord retracts to reduce visual distraction and keep the display area organized. The company uses a similar approach to prevent the theft of designer belts, which can cost hundreds of dollars each, with a belt lock security device. This allows hands on inspection of the belts but prevents thieves from pilfering many at once, as is the risk using a typical peg hook display. For securely showcasing luxury apparel and accessories in a way that optimizes customer-product interactivity, a growing number of retailers are also turning to electronic merchandise display security systems. “Retailers that want to display apparel or accessories have a range of more aesthetic, easier to use options with different sensors and alarms today,” says John Mangiameli, Se-Kure Controls Executive Vice President. “Sensors can clamp, or magnetically close for more delicate materials like silk or mink that a retailer wouldn’t want to put a pin through.” According to Mangiameli, tilt alarms, brick-like devices that typically detect either horizontal or vertical motion, can be attached to any item to alert employees to any unauthorized movement. “Horizontal tilt alarms, for instance, can be used on countertop jewelry spinners to allow them to be spun, but not picked up and moved without sounding the alarm horn,” he says. According to Mangiameli, some advanced electronic alarm systems are even designed to protect up to 20 garments at once. These can fit on wall, t-stand, waterfall and rounder displays while improving security, simplifying operation, and still allowing the customer to pick up and try on the garment. One such system operates with battery life of up to 16 months, and if the alarm is triggered, battery power can sustain a continuous alarm for almost seven days. For greater security, it incorporates a “visual memory” that keeps the system’s LEDs flashing until the tampered sensor is identified and corrected. It also has a “Where-It’s-At” option that flashes a light at the top of the display to help employees locate the source of the alarm. For high-end items like designer watches or smaller collections that require a display case, security systems are also available that protect up to twelve doors. For instance, with Se-Kure Controls Kontrol Card system for display cases, electronic locks are opened using RFID cards, eliminating the need for traditional locks and keys and if unauthorized access occurs, the alarm horn sounds. The system can be used for display cabinets, storage cabinets and drawers. With luxury fashion retailers facing greater competition from e-commerce, vendors that enhance the hands on buying experience of their customers, while minimizing theft with more aesthetic loss prevention devices, will gain a competitive edge. For more info, call 800-250-9260 toll free; fax: 847-288-9999; email info@se-kure.com; visit www.se-kure.com; write to Se-Kure Controls, Inc., 3714 Runge St., Franklin Park, IL 60131, USA.

Water Treatment Systems Turn to Ruggedized Fiber to Protect Against Disruptive Threats Water Treatment Systems Turn to Ruggedized Fiber to Protect Against Disruptive Threats Upgrade from copper to fiber optic cabling helps water treatment plant fend off lightning strikes, gnawing animals, environmental toxins, and other threats that can interrupt critical communications and control in remote locations Given the demands of an ever-increasing population and, in some regions, worsening drought conditions, water districts today are increasingly developing alternative water resources to supplement what has traditionally been a heavy reliance on groundwater. These alternative sources can include surface water from canals, rivers, or lakes and even saltwater treated by a desalinization process. Complicating matters, however, is that managing multiple water sources is like conducting an orchestra. Knowing which sources to draw from that day—and how much—is often based on variables such as the amount of recent rain, current water levels, and even annual average pumping limits. To do this, treatment plants must install sophisticated communication and control systems, not only within the plant itself, but also in remote areas such as remote wellfields or bodies of water. There, the equipment and cabling is exposed to all manner of unexpected threats ranging from lightning strikes, to gnawing turtles and gophers, environmental toxins in the soil or water, and even potential vandalism or security breach. As such, installers must pay particular attention to the type of cabling—often a choice between copper and fiber optics—as well as the type of “jacketing” that protects the strands of fiber or glass. Concerns of this kind recently drove the Tampa Bay Regional Surface Water Treatment Plant to upgrade from PE-89 outdoor direct burial copper cable to fiber optic cable. Tampa Bay Regional Surface Water Treatment Plant Since September 2002, Tampa Bay Water’s surface water treatment plant skims water from the Tampa Bypass Canal, Hillsborough, and Alafia rivers, when available. Some of that water is treated for immediate use at the Tampa Bay Regional Surface Water Treatment Plant, and surplus water is stored in a local reservoir. The surface water is treated through a three-stage process that begins by removing the color and particles from the water, disinfecting it with an ozone treatment to kill microorganisms, and then filtering it. The water is then disinfected a final time before it is blended with other water supplies and distributed. The plant was expanded in late 2010 to produce an annual average of 99 million gallons per day (mgd), enough to meet 50 percent of the region’s drinking water needs. In addition to the surface water, the plant continues to draw water from a groundwater source, the Floridian Aquifer, where they are permitted to withdraw an annual average of 120 million gallons per day (mgd) from 13 wellfields located in several nearby counties. To promote environmental recovery, 11 of the wellfields operate under a permit that recently lowered the annual average pumping limit from 192 to 90 mgd. Finally, a desalinization plant provides an additional 25 percent of the required drinking water. To manage the production at the regional wellheads, Tampa Bay Water carefully monitors the environment in and around the area. Groundwater production is also shifted in response to climatic and environmental factors. “This is where the communication and control comes into play,” says Robb Olsen of BCI Integrated Solutions, a company that specializes in cable installation. “They have to be able to generate their readings, as to how much water their wells are pumping, and then be able to turn the pumps on or off as needed.” According to Olsen, Tampa Bay Water opted to upgrade to more ruggedized fiber optic cabling after experiencing ongoing issues with the aging copper wire installed fifteen years prior. One of those concerns is related to lightning strikes that can break down communications and signaling. Lightning is such a regular occurrence in Tampa Bay that many refer to the city as the lightning capital of the country. “The copper cable was attracting lightning,” explains Olsen. “The strike doesn’t just affect the copper; the electrical charge can travel to connected equipment and destroy it.” Cattle also roamed the property, along with tortoises and gophers that often chewed on the insulation. “Because the local animal population was flourishing, this caused a problem,” says Olsen. “The animals were biting into the cables. This would cause more damage when copper was used.” In fact, to install the new fiber optic cabling, BCI Integrated had to work with local environmental groups prior to installation. In addition to these site-specific concerns, there are other potential disadvantages to copper. These include electromagnetic interference says Bill Prall, RCDD, sales engineer with Tampa’s Electric Supply Inc., a local distributor of electrical and low voltage products for necessary upgrades, including this project. “A lot of electromagnetic interference is picked up on copper,” says Prall. “Fiber optic technology is not susceptible to such interference. An operator can control valves quickly without having to worry about the system not doing what it is supposed to be doing.” Prall says that for this project they recommended DX Series distribution cable from Optical Cable Corporation (OCC) (occfiber.com), as well as the company’s RTC and WTC series of reliable and robust enclosures. OCC pioneered the development of tight-buffered cables for the most demanding military field applications in the early 1980s. OCC’s ruggedized tight-buffered fiber cables offer exceptional physical characteristics, including bend, crush, impact, and chemical resistance across a broad thermal operating range. Much easier to work with than its counterpart, “loose tube” cable, plenum-rated tight-buffered cable is designed for use indoors and outdoors, and overcomes the need to make splices, thereby enabling a much cleaner and quicker installation. When installed, this cable design requires only an easy termination. “Fiber optic products offer the highest degree of protection,” explains Prall. “The primary goal is to protect the integrity of the system.” With the fiber cabling now installed, the need for maintenance and upkeep has dramatically decreased. “With the copper, I used to get service calls on a regular basis about that wellfield,” adds BCI

A Monolithic Approach to Primary and Secondary Containment in the Field A Monolithic Approach to Primary and Secondary Containment in the Field Advanced flexible polyurea coatings, applied directly to the substrate or pre-applied to geotextile liners, provide seamless containment for field applications When used for primary or secondary containment, traditional coatings have been too inflexible and not sufficiently elastic to accommodate ground, concrete or metal substrate movement. This deficiency can lead to cracks or holes developing in both the substrate and the coatings, which can compromise containment. However, the formulation of tough, monolithic, flexible coatings such as polyurea are now resolving this issue. When applied directly to concrete or metal surfaces, polyurea not only reinforces and protects the underlying substrate but can also bridge gaps or cracks of 1/8” or larger. Furthermore, polyurea is now being pre-applied to geotextile liners that can be quickly rolled out in sheets to protect more heavily damaged surfaces or for use in applications such as dirt or gravel pads at drilling sites. Once installed, applicators need only coat the seams of the liners to create a monolithic surface that is ideal for containment. Containment Requirements At drilling sites, federal and state regulations mandate the use of primary and secondary containment systems to keep toxic or hazardous substances from escaping into the ground and potentially entering the water supply. Implied in this requirement is the understanding that primary containment (typically via a concrete or metal storage vessel that holds chemicals or liquids) is not foolproof. Though durable, metals corrode, concrete cracks and is porous as well, so will leach liquids if uncoated. This requires secondary containment, which often takes the form of concrete pits with barriers installed around the perimeter of a tank or other storage container. To protect these structures, coatings such as epoxies, tars, and polyurethanes are often applied as an added barrier of protection. However, these traditional coatings are frequently inflexible when cured and can crack along with the concrete. “Typical coatings do not hold up well to substrate movement or daily, seasonal, or process-related thermal expansion and contraction, which can lead to cracks and leaks,” says Jim Collins, co-owner of South Penn Resources, a company that creates containment systems in the Pennsylvania region. After considerable research and testing, Collins says he turned to an advanced polyurea system from VersaFlex, a leading manufacturer of spray applied polyurea for primary and secondary containment. When applied to substrates such as concrete or steel, the spray-applied waterproof coating creates a durable, seamless, flexible, protective barrier that stops leaks and strengthens the integrity of primary and secondary containment systems. The coating exhibits superior physical properties such as hardness, tensile strength, as well as crack bridging and elongation up to 400%, to create a robust, industrial-grade protective lining. “Polyurea can bridge cracks as well as flex at a rate similar to concrete and steel,” says Collins. “This not only helps it last but also seals the concrete so it does not absorb contaminants if there is a spill inside the contained area.” When compared to traditional coatings, Collins also appreciates the quick return to service possible when spraying the polyurea system for containment. While traditional coatings such as cementitious, epoxies, tars, and polyurethanes will prematurely fail if not installed under a relatively narrow range of temperatures, polyurea is designed for installation and use from -40°F to +350°F. It sets and cures quickly and will withstand decades of freeze-thaw cycling, as well as wide variations of temperature and humidity. “After spraying the polyurea, return to service is almost instantaneous, which can make a big difference in minimizing production downtime,” says Collins. “We coated about 8,000 sq. ft. of concrete in 12 truck-offloading areas that required drive-in containment with VersaFlex polyurea. Within minutes of spray application, trucks were safely driving across it.” Fast, Effective Containment in the Field Although spraying polyurea directly to the substrate has many advantages, for containment over soil, gravel, or even concrete that is too damaged to be effectively rehabilitated, pre-sprayed composite panels offer superior protection. This solution is particularly suited to field applications that must be able to endure heavy traffic from trucks loading or unloading materials. Although plastic liners that are seam-welded together are often used for such applications, they are more easily punctured and can bunch up under heavy use. “For primary containment at oil field drilling sites, we used to put various plastic systems on the well pads, but we moved away from that because plastic was not durable enough,” says Collins. Repairing plastic liners also presents a problem at the seams, when damaged areas are cut out and new sections welded in, says Collins. “The result is a patchwork liner with seams that are prone to failure due to improper welding as well,” he says. As a solution, Collins turned to geotextiles with pre-applied polyurea for its significant advantages in durability and reusability. “Polyurea products are so much more durable than plastics for containment systems,” says Collins. “When needed, we can custom apply more polyurea millage to geotextile panels and berms to accommodate even the heaviest truck use and vehicle abuse.” To verify the strength of the polyurea coating on containment mats and berms, in fact, Collins conducted a number of tests. “I ran an 11,000 pound skid loader onto a containment mat, stood the forks straight up and tried to puncture it – but it did not puncture through,” says Collins, who put the test video on South Penn Resources’ website. “We also ran 6,044 fully loaded water trucks across a containment system and it withstood it with zero holes and no compromise to the liner.” Collins credits both the durability of the VersaFlex polyurea as well as its extended recoating window for the ability of his company to extensively reuse its containment systems. “To reuse a containment system, we’ll cut it up into rolls, roll it up and move it. Then we’ll take it back out, respray certain areas, and reinstall the original containment system at another

Designing Microfabrication Lab Equipment with Research Flexibility in Mind Designing Microfabrication Lab Equipment with Research Flexibility in Mind Optimizing R&D labs usually involves vendor collaboration and planning to provide required versatility As research has become more complex, sophisticated cleanrooms have become a virtual necessity for a wide range of cutting edge physical science, material science, and biomedical disciplines. Due to the financial investment required for such facilities, both university and private R&D laboratories are designed and built to accommodate the needs of a wide range of researchers. This presents a challenge: few administrators have the experience to select and set up lab equipment with the versatility required to serve such a diverse group of users over decades of continually changing research. Now a growing number of lab administrators are optimizing their microfabrication equipment, both for current and future needs, by involving their vendors early in the process. This enables expert planning as well as the selection of standard equipment options that can improve safety, usability, and efficiency while cutting cost. “Often university lab administrators have never built their own cleanroom before, so they hire an architectural firm to do the design, but are still a little lost on how to lay out the equipment for all the different potential uses,” says Louise Bertagnolli, president of JST Manufacturing (Boise, ID). “Because universities are always pushing the boundaries of research, the equipment has to be very flexible so it can be used in ways not even conceived of yet.” A nationwide manufacturer of manual and automated wet processing equipment, JST’s mechanical, electrical, and chemical engineers have many years of experience in industries including semiconductors, both silicon and compound, MEMS, photovoltaics, LEDs, Flat Panel Displays, and sensors. Whether for compound semiconductor, nanotechnology, Micro-Electro-Mechanical Systems (MEMS), biophotonics, biomedical electronics, or creating solar power alternatives to traditional silicon wafer construction, much of the advanced research done in labs today requires microfabrication operations. This typically includes wet processing equipment for metal lift-off, stripping, etching, plating/coating, cleaning, and de-bonding. Dennis M. Schweiger, Senior Director of Infrastructure at the University of Michigan’s Lurie Nanofabrication Facility (LNF), feels that the right combination of user requirements and assistance from the equipment fabricator can make a significant difference in the design, layout, and operation of a wet processing station. The LNF is a world-class facility in all areas of semiconductor device and circuit fabrication, integrated microsystems and MEMS technologies, nanotechnology, nanoelectronics, nanophotonics and nanobiotechnology. The LNF is an open use facility with hundreds of users from various UM departments, as well as many other universities and businesses. Schweiger states, “Since we essentially rent lab space and equipment to our diverse users, it is important that we provide them with benches that suit their purposes well, from those who are processing wafers to those who may be doing very advanced research or testing on non-wafer components.” According to Bertagnolli, who has guided numerous R&D lab administrators through the equipment design and selection process, the main concern is about setting up the cleanroom and procedures to serve the needs of users, but the process is not always well defined and there are many unknowns. “When designing and laying out cleanroom equipment, it is important to talk with a vendor or consultant with the experience to help you achieve your evolving research goals,” says Bertagnolli. “It is also essential that they help ensure it is correctly set up, that the proper safety, operation, and maintenance procedures are in place, and that lab managers are properly trained to carry these out.” Bertagnolli says that maintaining safety and flexible function for wet processing equipment often requires selecting the most appropriate options from a number of technologies. This may involve various chemistries, temperature controls, chemical baths/dips, ergonomic designs, as well as cleaning, filtration, ventilation, safety, and disposal technologies. Designing Modular and Custom Parameters To facilitate the economical design and building of a wet processing equipment solution, many users insist on a standardized approach with customizable features that will best handle their applications parameters. For example, JST utilizes standard products and standard methodologies to design and manufacture equipment. The equipment is modular by design, allowing for easy changing and reconfiguration should process or product requirements change. Another powerful feature: each unit is designed with software that is capable of performing all tool functions, including those that are not required. With this, end users can create their own process, or recipes, with all sub-routines at their disposal. “We like to give customers added flexibility by programming their equipment to do everything that the equipment is capable of doing,” explains Bertagnolli. “This enables them to dial in applications, such as chemical concentrations. They can also turn various features on or off, depending on your process requirements. Even though they may not need some of the features today, they may want to turn them on in the future, which can be both economical and powerful.” Specifying the design parameters for many manual benches may not be as involved as those of automated systems. However, soliciting the opinion of equipment manufacturers regarding equipment design may be highly beneficial. “Certain processes like etchings and cleanings lab managers will want to be flexible enough to accommodate a wide range of users and projects,” says Bertagnolli. “We are often asked for tank construction materials that can withstand a number of concentrated acids, so part of design flexibility is ensuring you use the most compatible materials for the most acids.” “Another aspect to consider is properly separating, neutralizing, and disposing of all the chemistries involved after use, whether in drains or tanks for treatment or pick up,” she adds. According to Bertagnolli, having the vendor visit the user’s facility can contribute to equipment design versatility that can accommodate changes in lab use over the long term. “An eye toward optimizing working space, operating cost, or maintenance can go a long way toward creating a cleanroom that will serve the user community well now and in the future,” says Bertagnolli. Optimizing LNF’s Lab The LNF’s Schweiger

State of the Car Wash Industry: The Good, the Bad, and the Competitive Edge State of the Car Wash Industry: The Good, the Bad, and the Competitive Edge The industry is growing, but with rising competition and cost, operators must optimize operations to survive and thrive With recent economic growth in North America, the good news is that the car wash industry is growing. Consumers are buying more new vehicles, particularly trucks, which creates a greater demand to keep them clean, polished, and looking new. The bad news is that the car wash industry’s growth has attracted lots of tough new competition. This has placed downward pressure on pricing just as labor and utility costs are rising. Technological advances like sensors, keyless ignition, and driverless cars are also introducing complications in the market. To survive and thrive in an increasingly competitive car wash market, owner-operators must now pay close attention to operational details and select the best equipment and materials that will give them a competitive edge in wash quality, shine, efficiency, and total per car cost savings. Growing Truck Market Share With total U.S. vehicle sales on pace as of August 2016 to eclipse 16.98 million for the year, sales continue at a brisker pace than the 15.42 million average of the last two decades. In fact, the industry came off its sixth straight year of sales growth last year. Consumers, however, are opting for more cargo-passenger capacity and features like towing and four-wheel drive, pushing the light-duty truck (including pickups, SUVs, crossovers, large vans, and minivans) market share up to 58% of all vehicles sales in the first half of 2016. For car wash owners who have traditionally calibrated their equipment to wash smaller cars and sedans, the taller, longer, wider vehicles that consumers now prefer may require adjustments to their operation. This could include working with vendors to adjust equipment to accommodate these vehicles. Outshine the Competition As more car washes are built, local market oversaturation can become a problem. So how can owner-operators set themselves apart from new competitors with big checkbooks? “When we compete with big box retailers, we’ve got to keep our wash quality high, our service fast, and do the little things that they find hard to do,” says Justin Alford, co-owner of Benny’s Car Wash, with seven family-owned locations in Baton Rouge, LA, including express, exterior, full-service oil changes, and convenience stores with gasoline. Often this requires that owners maintain a hyper-focus on operational details and seek out the most effective wash materials and equipment for their market. With the fully integrated gasoline marketers, this is less likely to happen because the car wash business can be an afterthought. For example, instead of inefficiently having staff hand scrub, hard-to-clean, vehicle tires and wheels in tunnel washes, Alford uses an automated conveyor car wash brush specially designed to clean tires and wheels. The brush’s filaments vary in length between four to seven inches so that as a vehicle travels through the automated car wash, the longer bristles reach deep into wheel crevices while the shorter bristles clean the tire and wheel surface. “Instead of inefficiently hand scrubbing vehicle tires, wheels, and rims, particularly difficult big ones, we use something called the Poodle Brush,” says Alford. “Resembling a well manicured poodle, this brush is made for us by car wash supplier Erie Brush and Manufacturing.” “It gets into the nooks and crannies better than high-pressure sprayers with heated water and cleaning solution, and gives a better quality wash for our customers,” he adds. Troubleshoot Technology Among the issues that confront car washes today are rapid changes in technology, such as collision sensors, keyless ignition, and even driverless cars. On tunnel washes, for instance, cars are placed in neutral. But what do you do if a sensor thinks that wash equipment is a car and applies the brakes? Another problem occurs when cars have keyless ignition fobs. The technology can lock the doors or change gears from neutral to park if the owner walks away with the fob. “There’s no great solution to technology glitches right now because the last thing car manufacturers think about is how the car will be washed,” says Alford. “When a car’s sensors or keyless ignition is a problem, we have the owner ride in their car through the tunnel and have an operator follow to fix problems quickly. But in the long run, car manufacturers may need to create a Car Wash Mode to simplify the process for everyone.” Cut Labor, Enhance Quality Along with greater competition, the rising cost of labor and utilities means that car wash owner-operators have to optimize their labor and processes with the most effective equipment and materials to compete. “When we started 34 years ago, labor was $3.35 an hour and we charged $6.00 a car,” says Doug Seniw, co-owner of Prairie State Express Car Wash, an exterior express wash in Chicago, IL. “Now labor is $9.00 an hour and we charge $3.00 a car. Due to the competition, we’ve had to cut our price and streamline our business anywhere we could without cutting quality.” To optimize their process, Seniw has made a number of changes over the years. Previously, at the wash entrance his staff used nylon prep brushes to mop trouble spots on the front and back of cars such as the grill, headlights, and license plates. But this required excessive scrubbing to remove bugs, bird droppings, and other debris, and was not sufficiently gentle on the car surface. Seniw turned to prep brushes made of hog’s hair, actual hair that comes from hogs. This has the smallest diameter tapered filament, which helps to make it the softest. Since it is soft, tapered, and feathered at the tips, it tends to release grit and debris when properly lubricated and will not grind it into the car surface. Because of the taper, the hairs still retain stiffness for washing up close, if scrubbing is needed. For an optimal approach in the automated express

Department Store Loss Prevention: A Simpler, Less Intrusive Buying Experience Department Store Loss Prevention: A Simpler, Less Intrusive Buying Experience New options prevent theft of designer apparel, accessories, electronics, and power tools while enabling hands-on interaction with less clutter For department stores that offer a wide variety of clothes, accessories, electronics, and hardware, the customer’s retail experience can be just as important as loss prevention. Often the look and feel of the product on display in store, including the shopper’s ability to engage and interact with the product, can be crucial in the buying decision. While intrusive loss prevention devices cannot be a barrier to consumers in the sales process, retailers also cannot let expensive merchandise “walk out the door” due to shoplifting or employee theft. According to the 2016 National Retail Security Survey (NRSS), retailer inventory shrinkage accounted for 1.38 percent of sales – up $1.2 billion from the previous year. In addition, 47 percent of retailers surveyed reported increases in overall inventory shrinkage. The ideal way to display such designer merchandise is with innovative mechanical or electronic loss prevention devices, which may involve cords, sensors, an alarm console and related equipment. With online competition crimping margins and reducing brick-and-mortar retail staffing today, using effective theft deterrent devices is even more important. Now a greater array of options is allowing retailers to prevent theft and showcase merchandise more naturally with less intrusion. Security for Apparel and Accessories With apparel and accessories the focus of most department stores, any loss prevention device – whether a mechanical tether, alarm console or sensor – should not overshadow such products, or be cumbersome or difficult to maintain by employees. To meet this need, innovators in the industry offer a variety of loss prevention devices that secure these designer products with minimal visual clutter or intrusiveness. In the case of a haute couture handbag, for instance, it is essential for each shopper to see for herself how it feels on the shoulder, how it rests against the hip, as well as how it opens and how much storage it offers. Yet when some high-end items like designer handbags can cost $2,000 each or more, protecting against “grab and run” theft is critical. A single incident that can take only a few minutes can cost a retailer tens of thousands of dollars as an entire rack of merchandise is swept into a bag and out of the store. Against such theft, companies like Se-Kure Controls, a Franklin Park, Illinois-based manufacturer of retail product security devices, offer small, retractable, lockable cords that allow customers to examine handbags up close. When the shopper returns the handbag, the cord retracts to reduce visual distraction and keep the display area organized. The company uses a similar approach to prevent the theft of designer belts, which can cost hundreds of dollars each, with a belt lock security device. This allows hands on inspection of the belts but prevents thieves from pilfering many at once, as is the risk using a typical peg hook display. For securely showcasing luxury apparel and accessories in a way that optimizes customer-product interactivity, a growing number of retailers are also turning to electronic merchandise display security systems. “Retailers that want to display apparel or accessories have a range of more aesthetic, easier to use options with different sensors and alarms today,” says John Mangiameli, Se-Kure Controls Executive Vice President. “Sensors can clamp, or magnetically close for more delicate materials like silk or mink that a retailer wouldn’t want to put a pin through.” According to Mangiameli, tilt alarms, brick-like devices that typically detect either horizontal or vertical motion, can be attached to any item to alert employees to any unauthorized movement. “Horizontal tilt alarms, for instance, can be used on countertop jewelry spinners to allow them to be spun, but not picked up and moved without sounding the alarm horn,” he says. According to Mangiameli, some advanced electronic alarm systems are even designed to protect up to 20 garments at once. These can fit on wall, t-stand, waterfall and rounder displays while improving security, simplifying operation, and still allowing the customer to pick up and try on the garment. One such system operates with battery life of up to 16 months, and if the alarm is triggered, battery power can sustain a continuous alarm for almost seven days. It also has a “Where-It’s-At” option that flashes a light at the top of the display to help employees locate the source of the alarm. Security for Electronics and Power Tools In terms of retailing electronics, customer interactivity with the product as well as effective, non-cumbersome, loss prevention devices can be just as important. As such, department store loss prevention managers are learning from the successes of experts in the electronics industry. “We want the focus to be on the product, rather than on the power and security cords,” says Bill Jones, an AT&T regional Director of Asset Protection. “Some of the theft deterrent options on the market create quite a bit of clutter and look outdated.” To meet this need, innovators in the industry offer a variety of loss prevention devices that secure electronic products without the mess and clutter. A growing number of retailers, for instance, are turning to electronic merchandise display security systems like the Vantage II by Se-Kure Controls. While most systems require separate wires for security and charging the electronic device it protects, this system utilizes a single wire to provide both security and power. “One of the things that drew us to our display security system is how nice, clean and modern it looked to have the one cord,” says Kevin Lasky, project manager for Arch Telecom, a wireless retailer with 140 locations in 13 states. “There is no separate cable running up the side of the pedestal or coming out of the display to charge the phone. That was important to us.” Department store managers are finding additional benefits in such loss prevention devices for items ranging from electronics

Nursing Home Administrators Look to “Get Out of the IT Business” Nursing Home Administrators Look to “Get Out of the IT Business” Today’s Managed Service Providers help assisted living facilities and nursing homes focus on patient care without compromising private information or network security Many nursing home and assisted living facility owners and administrators are faced with the same challenge: how to maintain a reliable computer network that is compliant with industry requirements such as HIPAA. Fortunately, new options exist that can remove much of the burden of these requirements. These services, offered by IT experts known as Managed Service Providers (MSPs), can range from private, secure e-mail hosting to installing and managing a complete network run in the “cloud” (on remote servers) with all hardware, software, phones and even timely tech support provided. Best of all, these companies are able to monitor and remediate any network security issues to ensure compliance with HIPAA and secure payment transaction requirements. This, combined with a business model that is based on reasonable monthly fees and no upfront hardware or software investment costs, is helping nursing home and assisted living administrators effectively “get out of the IT business” and instead focus on more pressing issues related to patient care. The Inflexibility of Traditional Computer NetworksThe very nature of the industry lends itself to a more complex network configuration, since many nursing home groups consist of multiple facilities in different locations. As such, computer networks must be designed to tie all the facilities together securely – often from a central location or headquarters – while accommodating requirements such as shared network folders that can be accessed by all with those folders that should only be accessed by a specific facility. Complicating matters, most facilities now routinely install separate wireless Wi-Fi networks for patients and staff. Until recently, these networks required one or more IT staff members in-house, large capital expenditures for the initial hardware and software, and recurring costs for operating licenses, software and hardware upgrades, and general system maintenance. Moving to “the Cloud”According to Robert Williams, Founder & Owner of Compsys, a full-service MSP that regularly works with nursing home and assisted living administrators, the industry is migrating away from this approach and towards options “in the cloud” where information and software is run on private, secure, remote servers. “Cloud-based servers are managed by experts, and often provide a higher level of security than on-site servers, as data is copied and saved to duplicate servers so no information can ever be lost,” says Williams. Employees access the off-site server the same way they do an in-house network, by logging in using a username and a password, so the transition is seamless for all computer users despite their physical location. Since the servers are located off-site, nursing homes do not have to worry about maintenance or crashes, says Williams. Instead, the MSP continuously monitors all hardware/software and handles issues quickly, should they arise. Rebecca Norman, IT Coordinator for Southern Administrative Services, a medical group with 38 nursing homes across Arkansas and headquarters in Louisiana, believes outsourcing her IT to a company like Compsys provides several key advantages to her nursing home group. “Switching the company’s servers to a cloud-based system has made things a lot easier,” says Norman. “We don’t have to worry about something crashing, keeping up with security, software updates, or worrying about whether or not the network is in compliance. Our MSP takes care of all of that for us.” Although she is the IT coordinator, Norman admits she knows little about the intricacies of computer networks. With an MSP, however, that is not required. “They’re very proactive and let me know right away if a problem occurs, offering troubleshooting solutions immediately. I can rest easy because I know we are in good hands,” adds Norman. Network Compliance with HIPAAAnother key issue for facilities is remaining in compliance with regulations such as HIPAA (Health Insurance Portability and Accountability Act) and PCI DSS (Payment Card Industry Data Security Standard). Nursing homes are required to implement security measures to handle the patient’s protected health information (PHI), including any electronic data. Keeping in compliance at all times can be challenging for smaller organizations, so an IT that understands HIPAA compliance requirements will set up safeguards to protect medical data confidentiality. For example, monitoring software can be installed on workstations to ensure that antivirus and malware software is up to date, and immediately sends an alert to a designated staff member if a breach in compliance occurs. The compliance officer can easily access the recorded data and review what needs to be done to regain compliance swiftly. As for payment handling, PCI DSS security standards ensure that companies can accept, process, store or transmit credit card information while maintaining a secure transaction environment.Cathy Parson, owner of Hope Healthcare, a medical group that runs nine nursing homes in Arkansas, says she is planning to accept credit cards over the phone soon and has requested Compsys, who previously set up her payroll system, to develop her new payment system. “Trusting them with our compliance requirements is vital to my business,” says Parson. Additional OptionsAnother IT aspect that can be moved off-site is a private, secure e-mail server, over which the nursing home retains full control, rather than the MSP. In fact, the server is so secure, even the hosting provider cannot access it, which fully preserves patient confidentiality and privacy and meets compliance requirements. Rather than having to purchase or lease workstation hardware (monitors, keyboards, mice) and software up front, a MSP can even provide a full turnkey solution by providing all required items and billing customers a monthly fee. As part of this service, hardware is replaced every three years at no additional cost. This can be a good option for facilities that are new, or haven’t been upgraded for a while. No One-Size-Fits-All SolutionCompsys’ Williams admits that outsourcing big chunks of a computer network to an MSP is not always a straightforward process since

Dual Pane Windows Do Not Stop the Noise Dual Pane Windows Do Not Stop the Noise High Tech “soundproof” windows dramatically reduce noise, increase energy efficiency, and install in as little as one hour each When the uproar outside is simply too much – barking dogs, honking horns, or blaring sirens, not to mention lawnmowers, leaf blowers, and the noisy neighbors – cutting the clamor can be vital to reclaiming some much needed peace and quiet. For years homeowners seeking to get rid of the irritating outside noises have been repeatedly advised to invest in dual pane windows. That solution will never solve any serious noise issues due to one simple fact – double pane windows were not designed to keep noise out. While homeowners can expect only a 0% to 20% noise reduction with dual pane replacement windows, true soundproof windows can cut the outside racket by up to 95%. Now homeowners can install such soundproof windows, using technology that recording studio professionals trust, in their own homes. Solving the Noise Problem Dual pane windows are well designed to keep out the heat and cold, but not the noise. While the seals of a new window provide some noise reduction, the two pieces of glass in dual pane windows are separated by an air space, and sealed into one solid glass unit. Like a drum, this causes both pieces of glass to vibrate at the same time. This drum effect defeats the noise reduction benefit of dual pane windows. “Our fourth floor condo is near an intersection and a bus stop, so the sound of braking, accelerating, honking, and sirens interrupted our sleep at all hours of the night,” says Doug Alexander, a condo owner along with his wife in White Rock, BC, Canada. “During the day, the sound of leaf blowers, slammed car doors and trunks, and the occasional parking lot car alarm also wore on our nerves.” While the Alexanders already had dual pane windows throughout their condo, the windows were not up to the task of reducing exterior noise to a livable level. “With older windows like ours, the window seals degrade so the noise comes in almost like the windows are open,” says Alexander. The Alexanders considered purchasing dual pane replacement windows but balked at the added cost and disruption of having to replace the window frames, flashing, and caulking. They also anticipated difficulty getting approval for the project from their homeowner’s association. These problems led them to search for a new solution. The Alexander’s research led them to Soundproof Windows, Inc. a company with expertise engineering windows for some of the most noise sensitive environments in the world, such as recording studios. After consulting with the company, they decided they had found the noise reduction solution they sought. They also received guidance from the company on which exact windows to soundproof and to what specification to achieve the greatest result. The company has adapted recording studio window soundproofing technology for residential homes by creating a secondary soundproofing window that installs inside, behind the existing window. The product is custom designed specifically to match – and function – like the original window. Installation is simple, straightforward, and fast – leaving little to no mess at all. The inner window essentially reduces noise from entering on three fronts: the type of materials used to make the pane, the ideal air space between original window and insert, and finally improved, long-lasting seals. The combination can reduce external noise by up to 95%. The first noise barrier is laminated glass, which dampens sound vibration much like a finger on a wine glass stops it from ringing when struck. An inner PVB layer of plastic further dampens sound vibrations. Air space of 2-4 inches between the existing window and the Soundproof Window also significantly improves noise reduction because it isolates the window frame from external sound vibrations. Finally, the company places spring-loaded seals in the second window frame. This puts a constant squeeze on the glass panels, which prevents sound leaks and helps to stop noise from vibrating through the glass. These spring-loaded seals stay as acoustically sound 15 years down the road as they were on day one. Some other window companies offer soundproofing solutions. Most offer acrylic windows that were originally designed to insulate. Acrylic that is 1/8” or ¼” thick is not acoustically very good. It may offer up to a 30% acoustic reduction, but in any noisy environment that is still insufficient. Also, they do not open and close like existing windows. “The Soundproof Windows cut our exterior noise to about 1/4 of what it used to be,” says Alexander, who along with his wife self-installed four of the windows in about four hours. “Now we sleep soundly at night, and it’s much easier to talk face-to-face or by phone without having to talk over noise. If tires squeal, a car honks, or an ambulance goes by outside, it’s faint and no problem at all.” While the Alexanders did not require a Sound Transmission Class (STC) rating for their home improvement project, the most objective measure of sound reduction is the window’s STC rating. In this rating system, the higher the number the more noise is stopped. Most standard single pane windows typically rate around a 26 STC. Installing a high quality, dual pane window would increase a homeowner’s potential rating to a 27 to 32 range. In comparison, the acoustic soundproof windows are lab tested and earn a 48 to 54 STC rating and can go well beyond this level of soundproofing, if required. “Soundproof Windows advised us to use 1/4” thick glass panes about 2-1/2” from our existing windows,” says Alexander. “Our advisor told us that thicker panes could provide even more soundproofing, but that in our case thicker panes were not required because external noise would likely penetrate our walls and offset the benefit.” Cutting Energy Cost and Draftiness Converting to soundproof windows can also significantly reduce energy costs. The new inner window

Smoke Detector Alternative Promises Earlier Detection, Less Disruption in Healthcare Settings Smoke Detector Alternative Promises Earlier Detection, Less Disruption in Healthcare Settings Aspirating, addressable smoke detection technology transforms approach to smoke and fire hazard monitoring while promising less disruption to patients For decades, traditional smoke detectors have been used to protect patients and personnel at healthcare facilities from the danger of smoke and fire – protection that is mandated by the NFPA (National Fire Protection Association). Now, however, a new approach using more sophisticated, established smoke detection technology is contributing substantial benefits for healthcare facilities: lower overall costs, earlier detection and less disruption to patients during NFPA mandated annual inspection and testing. Traditional Smoke DetectorsTraditional spot smoke detectors are installed in each room or space and connected to a central fire alarm panel by low voltage electrical wiring. When significant amount smoke accumulates in the chamber of one of these smoke detectors, the alarm sounds. Although there are addressable systems on the market that can identify the specific room where such a threat occurs, many are not addressable and so only identify the zone. While spot smoke detectors are reliable and relatively easy to install, NFPA regulations also mandate annual inspection and testing of each unit. This tedious and time-consuming process requires a fire alarm contractor to enter each room, introduce smoke directly into the detector and verify that it functions properly. This is often covered under ongoing maintenance contracts where fire alarm contractors make a significant amount of their profit. In a healthcare environment, however, this can be extremely disruptive to patients, doctors, nurses and hospital personnel. The problem is exacerbated in psychiatric wards or hospitals, or for those in drug recovery, that are potentially even more sensitive to interruptions. Surgical rooms, NICUs, PICUs and emergency rooms are also an issue, given the sterile environment. For Jeremy Robison, Facilities Director/Safety Officer at Sonora Behavioral Health of Tucson, AZ, which is part of the larger Acadia Healthcare Group, the annual inspections required significant planning. “For our patients, anything out of the ordinary, such as loud noises, can set them off,” Robison explains. Once he became aware the maintenance provider would be coming for an inspection, Robison says he would send out advanced notifications by e-mail to alert both personnel and patients, as well as to warn them of possible loud noise associated with testing. He would then have to figure out how to ensure that staff and patients were out of the rooms at specific times – a process that often required some creativity. “One of the things I would try and do is schedule inspections for mealtimes, when the entire unit would be in the dining room,” says Robison. Aspirating TechnologyIn smoke detection, more advanced technologies that provide earlier warning detection exist. These systems work by aspirating – or drawing in air – from each room through small, flexible tubing. The air is then analyzed to identify the presence of minute smoke particles in a continuous process. For almost 40 years, aspirating smoke detectors (ASD) have been used for the most sensitive applications where early detection of smoke or gas is critical, such as in cleanrooms, data centers and telecom facilities. Among the pioneers in ASD technology was the VESDA (Very Early Smoke Detection Apparatus) system first introduced in the early 1980s by Xtralis. The company has since evolved that technology to offer a system that combines the reliability and early detection of VESDA with addressability in each room. The system, called the VESDA-E VEA, consists of small, flexible tubes that draw air through small, unobtrusive sample points in each room. The air is analyzed using sophisticated laser-based technology at the central unit located within 300 feet. As a multi-channel, addressable system, the VEA central unit can pinpoint the location of the alarm. A single system supports up to 40 sample points and can be extended to 120. For Robison of Sonora Behavioral Health, the addressability of the system had great appeal. He says the VEA systems was installed after it was specified by a consulting engineering firm during construction of a new building at the site in November of 2016. “I like how, if a smoke detector goes off in room 401, it tells you there is issue in room 401,” says Robison. “I don’t have to go through the entire unit, checking every one until I finally come across it.” The system is also sophisticated enough to allow for three levels of sensitivity to differentiate a fire from a patient smoking in a room, for example. This further minimizes disruption by reducing false alarms. Even with these benefits, one of the primary advantages of an aspirating smoke detector system is its ease of maintenance, inspection and servicing. In compliance with NFPA 72 Chapter 14 requirements, systems like VEA do not require the contractor to enter each room. Instead, servicing and testing can be performed at the central unit and only takes a few seconds per sample point. In this way, the fire alarm contractor can complete the inspection at any time without having to move patients or access restricted areas. By some estimates, this can greatly reduce maintenance and inspection costs and reduce the total cost of ownership of the fire alarm system by up to 60%. Finally, since the VEA sample points are much smaller than regular smoke detectors, they appear less obtrusive. They can also be placed where spot smoke detectors would be difficult to reach, such as high ceilings, in restricted areas, or where new electrical wiring installation would be costly. Tim Callander, Partner at GB Technologies, a full service limited energy contractor in Burnsville, MN, that provides low voltage design and installation of fire alarm, access control, and video surveillance systems, see several advantages to a smaller sampling point. “As someone that works in the industry, when I walk through a building I’m looking at the all various fire alarm devices that are on the walls and ceilings,” explains Callander. “The VEA

Going Beyond the Catalog Approach for Car Wash Equipment Going Beyond the Catalog Approach for Car Wash Equipment Brush manufacturer willingness to customize a range of options is helping operators adapt to market changes and optimize their process In the conveyor car wash industry everyone wins when car wash owner-operators can thrive by offering customers a better wash while still maintaining a healthy profit margin. Yet as vehicle dimensions change and people further customize their cars and wheels, the standard catalog options are often not enough to get vehicles clean without taking additional time, labor, and resources. While modifications to standard catalog equipment options can accommodate these changes, traditionally most manufacturers – particularly those overseas – are not willing to do this. However, some North American brush manufacturers are aiming for a more collaborative approach with operators. This includes customizing a wide number of options, such as special colors that correspond with your logo, foam taper and length, cloth taper and length, or filament taper, length, width, height, longevity, and even mounting capability. These allow an owner to accommodate market changes and provide a superior wash while enhancing the bottom line. Cleaner Wheels for LessFor Earl Weiss, owner of four conveyor car wash locations in Chicago, IL, one of the biggest challenges is cleaning wheels when dirt and brake dust gets into the nooks and crannies and typical cloth or foam material does not sufficiently get it out. “If you run a low price exterior wash, it really hurts your profit margin to spend an extra 20-30 cents a car for high pressure water and cleaning solutions, plus the cost of electricity and equipment, just for the wheels,” says Weiss. Weiss believes he has found a better, less costly approach to clean wheels that uses his existing equipment with some modification from his supplier, Erie Brush & Manufacturing (eriebrush.com), a Chicago, IL-based manufacturer of car wash products and detailing supplies that has invested in a wide range of equipment to accommodate customer preferences. He has customized his rocker panel, side, and wrap around brushes, substituting filament for cloth in a number of areas, such as on the bottom 10” for lower details, and on the bottom 20” for van high side brushes. “Using equipment rotating in opposite directions, I clean the wheel about four times with filament,” says Weiss. “I get a nice clean wheel at a much lower cost than using high pressure water and cleaning solutions.” The key to this, says Weiss, is how Erie figured out a way that allows filaments to easily slide into the c-channel core that secures cloth and foam to his rocker panel, side, and wrap around brushes. “The filament pieces slide in and out so I don’t have to change brush cores,” says Weiss. “I just tell my equipment supplier the length and height of filaments I want, and I get them. I’m experimenting to find the best combination of filament and cloth.” Weiss encourages other car wash owner operators to think “out of the box” by going beyond standard brush options. “Car wash equipment manufacturers may think they have the latest and greatest, but until it is put into operation they don’t really know what the issues will be,” says Weiss. “I’ve found that customizing my brushes and filaments gives me the flexibility I need to optimize my wash process.” Custom Cleaning CoverageAs maintenance manager for the Boise, Idaho region of Mister Carwash, the largest full-service car wash chain in the United States, Tim Biagi is always looking to improve operations. To optimize cleaning for a variety of challenging vehicle types, Biagi experiments with the taper of certain brushes and with cloth and foam lengths. Instead of the stepped brush filaments common in the industry, which resemble “stair steps” and leave a coverage gap between each “step”, he prefers tapered brushes from his brush manufacturer, which he feels provide better cleaning coverage over vehicle surfaces. “We may change the taper on the upper part of a wrap around or van brush, so the brush taper better fits the contours of the vehicles we clean, which have become more aerodynamic and less boxy over the years,” says Biagi. “We change cloth or foam length to better clean the tops of taller vehicles like vans, trucks, or SUVs. Our supplier will modify brush taper as well as cloth and foam length to our specifications.” To reach higher on tall vehicles, which have grown taller in the market, he also requested a taller rocker panel brush. This required a longer custom brush core and an adapter plate. “Our original rocker panel brush was 21” high, and the ones we use now are 26” high,” says Biagi. When he noted that his high volume operation was wearing out rocker panel brush cores too quickly, he contacted his brush manufacturer to see what could be done to lengthen life. “They created a core with a special coating that has extended our brush core life by at least 50%, and we haven’t changed it yet,” says Biagi. He again sought the help of his brush manufacturer to handle the faster wear at the bottom of his wrap around foam brush cores, due to the many vehicles with trailer hitches going through his washes. “The bottom part of the brush core was wearing out twice as fast as the top, so they made us a two piece core,” says Biagi. “This makes it easy to replace the bottom part separately to further lengthen core life.” Getting into Tight SpotsWhen Doug Seniw, co-owner of Prairie State Express Car Wash, an exterior express car wash in Chicago, IL, sought a better way to clean vehicle nooks and crannies, which have become more common with modern styling, he turned to his brush manufacturer. “On automated equipment, the wider cloth and foam slits just don’t clean well because they don’t get into tight spots, such as car styling grooves or under and around side mirrors,” says Seniw. “There are a lot

Solving Complex Adhesion Problems with Plasma Solving Complex Adhesion Problems with Plasma When traditional chemical adhesives fail to sufficiently bond dissimilar types of materials, engineers often turn to plasma treatments to solve complex adhesion problems. Whether bonding metal to plastic, silicon to glass, polymers to other polymers of different durometers, biological content to polymeric microtiter plates or even bonding to polytetrafluoroethylene (PTFE), plasma can be used to promote adhesion. Adhesion promotion can be achieved by increasing the surface free energy through several mechanisms, including precision cleaning, chemically or physically modifying the surface, increasing surface area by roughening and primer coatings, according to Michael Barden of PVA TePla, a company that designs and manufactures plasma systems. “It is not a question of whether plasma is effective or not,” says Barden. “Plasma is the king of surface activation and the best technology available. It just depends on the circumstances of the application.” Plasma is a state of matter, like a solid, liquid, or gas. When enough energy is added to a gas it becomes ionized into a plasma state. The collective properties of ions, electrons and radicals, can be controlled to change the properties of surfaces without affecting the bulk material. In this way, plasma is a powerful tool in solving surface preparation problems such as precision cleaning and decontamination, increasing surface wettability and adhesion promotion. In addition, plasma can also be used to polymerize monomers onto surfaces through Plasma Enhanced Chemical Vapor Deposition (PECVD) to provide thin film coatings. The net effect is a tremendous improvement in bonding. In some cases, up to a 50 times bond strength improvement can be achieved. Increasing surface EnergyFor a majority of applications, plasma treatments are utilized to increase the surface free energy of the material. Surface energy is defined as the sum of all intermolecular forces that are on the surface of a material, the degree of attraction or repulsion force of a material surface exerts on another material. When a substrate has a high surface energy, it tends to attract. For this reason, adhesives and other liquids often spread more easily across the surface. This wettability promotes superior adhesion using chemical adhesives. On the other hand, substrates that have a low surface energy – such as silicone or PTFE – are difficult to adhere to other materials without first altering the surface to increase the free energy. There are several plasma methods to increase surface energy, including physical and chemical plasmas along with PECVD coating surfaces. In addition, plasma can increase the surface area of bonding by nano-roughening a surface. Surfaces that are highly ordered, or very crystalline, tend to have very low surface energies. To disrupt that order, ionized plasma gas is utilized to bombard the surface. The most common and affordable options are helium, nitrogen and argon. According to Barden, the selection of the type of gas is determined by the amount of ion momentum required to disrupt the surface order. “To create more of an effect, gases with higher atomic masses can be used,” explains Barden. “At one end of the spectrum you can use helium for a light impact on the surface, whereas argon, which has 20 times the atomic mass, will impact the surface with much higher force.” This creates a surface with a high dispersive effect, another way to say high wettability. Another method of increasing surface energy is to create a polarizable group on the surface by utilizing chemical plasma. For example, O2 plasma can be used to create surface hydroxyls which allow liquids to spread through hydrogen bonding mechanisms. Adhesion to non-stick coatingsPlasma technology can also be used to control the surface chemistry of PTFE to improve bonding, not only for adhesives, but also inks, coatings, and biomaterials. PTFE and other fluoropolymers are known for their low coefficients of friction, exceptional chemical resistance and biocompatibility. They also offer high melting points, low dielectric constants, and resistance to flammability. However, the application of PTFE is often limited due to the material’s inability to be adhesively bonded to other materials. It has an inherently low surface energy and poor polarizability. “When a surface is really hydrophobic, like Teflon, it’s very difficult to bond to it,” says Barden. “If you apply a liquid or adhesive, it just won’t spread effectively.” Fortunately, adhesion properties of PTFE can be dramatically improved using PECVD techniques. The process creates a coating with polar functional groups on the surface that act as excellent anchors to either hydrogen bond or covalently attach hydrophilic coatings. Although ammonia gas plasma activation is traditionally used for this purpose, PVA TePla has developed an alcohol PECVD process that improves bonding strength 1.5 times over ammonia and 8.5 times over the untreated surface. The process also extends surface activation lifetimes. Whereas downstream processing and staging time was once confined to a six-hour window, it now extends several weeks, providing more flexibility in manufacturing environments. This technique opens the door to new methods of chemically engineering surface properties of PTFE. The ability to selectively functionalize the surface with primary amines, hydroxyls, and carboxylic acids means that engineers can now broaden the use of this material in medical technology. Adhesion of Biological MoleculesGas plasma can also provide surface conditioning of in vitro diagnostic platforms prior to the adsorption of biological molecules (protein/antibody, cells, carbohydrate, etc.) or biomimetic polymers. This includes precision cleaning of the substrate at the molecular level, along with raising the surface energy to improve surface assimilation of the intended content. “Microtiter and multiwell plates are often made of polystyrene, which is extremely hydrophobic. Water will bead on it,” says Barden. “However, if you treat polystyrene with oxygen plasma it will become very hydrophilic, so water spreads everywhere. This allows aqueous solutions containing biological content to spread and deliver biomolecules to the surface while providing a hydrogen bonding platform to adhere them.” However, some in vitro diagnostic substrates require more selective surface chemistry to immobilize a customer’s proprietary molecules. For this, PVA TePla has recently developed methods for chemically

Blurring the Lines Between OEM and Aftermarket Parts for Gensets Blurring the Lines Between OEM and Aftermarket Parts for Gensets Branded replacement parts manufacturers are increasingly “acting” like OEMs in approach to quality control, utilization of sophisticated measurement systems and adoption of lean manufacturing techniques to produce consistent, high-quality parts. Over the past few decades, the acceptance of replacement parts suppliers for engines used in the power generation market has evolved significantly. Today, the consistent quality, availability, coverage and warranty of products from branded aftermarket suppliers are increasingly rivaling those of their OEM counterparts. Those attributes are often particularly essential when it comes to parts – whether OEM or branded aftermarket – for servicing gensets that supply primary or standby electric power, or are integrated with UPS systems. For example, a wide variety of industrial users require gensets for power at construction sites, mining and military operations and offshore oil rigs. On-time production and worker safety at these types of facilities is highly dependent on the reliable availability of electric power. Many industrial users rely on gensets to provide standby power, which may be critical to continuing production, and to keep costly equipment running during blackouts. Others may use natural gas or diesel-generated power to provide electric energy as an alternative to grid power during specific hours in order to avoid high “peak” energy costs. In some applications, gensets are integrated with UPS to provide extended backup capability. These may include data centers, healthcare facilities and pharmaceutical labs, where continuing patient procedures, maintaining critical temperature ranges, or preventing data losses are critical concerns. The trend toward using branded aftermarket parts suppliers to maintain gensets and many other heavy-duty applications has resulted largely from the ability of some of these suppliers to deliver high-quality parts on time at competitive or even lower price points. In fact, many leading branded aftermarket suppliers are increasingly acting like OEMs, adopting advanced manufacturing and quality assurance programs, incorporating lean manufacturing techniques, or offering products individually as well as in kits and sets to facilitate engine overhauls. Not only are these aftermarket suppliers meeting stringent OEM tolerances, but in some instances they are also providing value-added marketing and customer support services, providing excellent availability, comprehensive warranties, and even parts research capabilities. Such value-added services are increasingly convincing heavy-duty users, parts resellers and service shops to source replacement parts from aftermarket suppliers. Consistent Quality, Competitive PricingQuality Diesel Service (Amelia, LA) was one of the nation’s first independent diesel shops to offer 24/7 parts and service for Caterpillar engines to the oilfield industry. Over the last 30 years, Quality Diesel Service has also established itself as a leading remanufacturer of Caterpillar® engines and marine gear. “We know time is money in the oil industry, so we stock one of the largest inventories of Cat® application replacement parts and remanufactured engines in our market,” says Vincent Bourgeois, Parts Manager. Since 1987, Quality Diesel Service has provided its Cat customers with parts from IPD, a branded aftermarket supplier of parts that were equivalent and interchangeable with OEM. Headquartered in Torrance, CA, IPD manufactures and distributes a broad range of replacement parts for Caterpillar, Cummins, Detroit Diesel, Volvo and Waukesha engines. Products include such popular items as pistons, cylinder liners, valvetrain parts, engine bearings, and gaskets. Many users and service providers say that the advanced manufacturing and quality assurance capabilities of aftermarket suppliers such as IPD has made them comparable to OEMs in terms of quality while offering the advantage of highly competitive prices. “I think an after market company like IPD has to prove themselves, so that’s why they go the extra step to make sure the product is right,” Bourgeois explains. Since 1985, Quality Diesel Service has sourced a range of parts from this supplier, including high-mortality items such as wear parts like your pistons, liners, bearings, gasket kits and seals. While quality and availability are essential to meeting Bourgeois’ requirements, he says that a somewhat lower price and comprehensive warranty are a “plus” influence on his choosing IPD. He also says that this supplier has made some design improvements to replacement parts such as pistons, changes that can lead to improved service life. Diesel Exchange Incorporated, located in Springfield, MO, also uses branded aftermarket engine parts on a selected basis. Founded in 1992, the company has developed into an award-winning remanufacturer of diesel engines. For the past six years, those have included various Caterpillar models. Among the users of gensets are customers in the construction, military, and oil & gas industries. For those and other Cat applications, Diesel Exchange has sourced parts such as cylinder kits, bearings and gasket kits from IPD. According to Steve Hendrick, Diesel Exchange president, this line provides the same quality and availability of the OEM dealer, yet also saves on costs. “We closely evaluate this supplier’s parts with those of the OEM, and they compare very well, “Hendrick says. “I think today’s technology has developed to the point where quality-conscious aftermarket suppliers can consistently produce the quality that used to be available only from the OEMs.” Other diesel genset service providers, particularly machine shops, are more aware of the manufacturing capabilities of this manufacturer. “We use CNC equipment in our machine shop, so we’re fully aware of the capabilities of those machines in meeting precise tolerances,” says Ted Short, owner of Wesley Machine (Winnipeg, Manitoba). “We know that IPD uses the latest technologies in manufacturing, inspection and other quality assurance procedures, which result in engine parts that consistently meet the tolerances and quality equal to that of the OEMs, in my opinion.” In some cases, such suppliers also provide valuable technical services, such as answering questions about issues such as parts interchangeability. IPD parts information and applications data is also available via an online database, and failure analysis assistance information through technical bulletins and service videos. Advancing Manufacturing MethodsSome aftermarket suppliers achieve brand name acceptance through quality that results from incorporating innovative methods on the production line. At IPD, for example, the

Revisiting GHS Label Compliance One Year After OSHA’s Deadline Revisiting GHS Label Compliance One Year After OSHA’s Deadline New survey shows over 21% of companies did not meet all GHS compliance requirements One year after OSHA’s June 1st, 2016 “Globally Harmonized System” (GHS) label end user deadline, over 21% of companies had not yet met all requirements, according to a new survey. The survey, conducted by Occupational Health & Safety (OH&S) magazine and Avery Products Corporation, an industrial and consumer label provider, reveals the perceived top barriers to GHS label compliance. Fortunately, the tools and strategies exist that can help small to mid-sized companies achieve GHS label compliance rather quickly and inexpensively. With higher OSHA penalties making non-compliance more costly, taking advantage of these tools and attaining compliance is more important than ever. “The OSHA GHS label deadline for end users has come and gone, and it is now a costly compliance issue,” says Christine Webb, CSP, a consultant at Avitus Group, a U.S. based provider of services that allow small companies to strengthen and grow their businesses. Some of these services include safety, compliance, training, payroll, and more. According to Webb, who is also a former OSHA compliance officer, last year Congress enacted a bill that allowed federal agencies to raise their fines, which have not been updated in decades. “OSHA increased its fines by 78%, so a more severe citation that could cost up to $7,000 previously can now cost over $12,000,” says Webb. “Not having appropriate GHS labels on secondary containers is one of the easiest compliance issues to spot and cite.” In an industrial setting, chemical formulations that could require GHS labeling range from industrial primers, coatings, and sealants to lubricants, greases, cutting oils, and rust removers to acid, alkaline, and solvent based cleaners to degreasers, surfactants, disinfectants, and sanitizers. Overcoming Barriers to Compliance1) GHS Label ContentAccording to the survey, over 26% of respondents stated that finding and placing compliant GHS content onto the label has been the most challenging part of the labeling process for them. Too often this has involved tracking down difficult to obtain updated safety data sheets, determining the key data, and printing it on the GHS label in the correct format, which does require GHS pictograms. On each GHS label, six specific items of data are required: Product Name or Identifier; Hazard Statement; Signal Word; GHS Pictogram symbols; Precautionary Statement; and Supplier Information. In place of the familiar black and white pictogram symbols previously used in safety labeling, GHS labels require pictogram symbols that convey hazard information with a red diamond border. “A lot of people still don’t fully understand GHS labeling requirements, particularly at the small to mid-sized company level,” says Webb. “They are unsure of what goes onto a GHS label and how to get it.” Webb notes that as a safety and compliance consultant, she often shows clients how to use free GHS label software available online and how to print labels from their desktop printers.She says that such GHS label software is intuitive, like using an app or a Microsoft Word template. The crucial GHS label data can be accessed almost instantly from online databases and formatted to GHS requirements. Much of the necessary information can be obtained, in fact, by simply entering a substance’s Chemical Abstracts Service (CAS) number. “Avery provides a lot of the GHS label chemical info on their website,” says Webb. “My clients save it on their PCs, so they don’t have to go back online. They print GHS labels from desktop printers, and put the labels on containers as needed.” The software includes the pictograms and GHS compliant statements needed for GHS labeling, allows customizable text, and insertion of company logo or other images. For more sophisticated uses, it can generate 18 types of barcodes and has a sequential numbering feature to add lot numbers or other variable data. No download is required since the cloud-based GHS software operates from the Avery website at www.avery.com/GHSLabel, and GHS, HMIS, and NFPA labels can be securely saved online or to a computer. The software is also capable of printing other safety labels such as OSHA, ANSI, and Arc Flash labels. 2) GHS Label DurabilityOver 24% of survey respondents indicated that another challenge was finding durable labels that can withstand chemicals and harsh environments. According to Webb, who consults with clients from a wide range of industries, some people mistakenly try to use regular office-grade labels for GHS applications, but find that the labels peel or the ink fades in tough workplace settings. “GHS labels must be durable to stay compliant,” says Webb. “In machine shops and auto body shops, for instance, the labels must resist oil, grease, and solvents, and in restaurants and kitchens hold up to harsh cleansers and disinfectants. In such applications, GHS labels can withstand solvents, degreasers, cleansers as well as abrasion and moisture.” Durable synthetic labels like Avery UltraDuty™ GHS Chemical Labels are chemical resistant, tear resistant, abrasion resistant, and constructed with a high-performance adhesive that is waterproof and passes a 90-day seawater submersion adhesion test. Unlike typical labels, which crack and harden in harsh conditions, they are UV resistant with 2+ years of outdoor UV life. They are also temperature resistant, can be applied as low as 10° F, with adhesive service temperatures that can range between -40° F to as high as 300° F. For extra protection in harsh environments, Webb likes to use an additional laminate over the top of GHS labels. Avery, for instance, offers such labels with a clear laminate so no lamination machine or additional layer of tape is needed. The material is UV and water resistant, and resists scuffing, tearing and smudging, making them ideal for use in warehouses, storage areas and worksites. 3) GHS Label SizeAccording to the survey, almost 11% of respondents stated that “finding labels that fit my containers” was a problem. For end users, GHS compliance is required for chemical formulations purchased in bulk containers for cost savings,

Tear Out or Replace: Tear Out or Replace: Facility Managers Face Critical Decision WhenReplacing Aging Induction Units Many facilities built in the 70s and 80s continue to operate and maintain aging induction-based air conditioning units originally installed in each room or space. Not to be confused with fan-driven systems, these quieter, more efficient alternatives have no fans, blowers or moving parts and so can continue to operate for decades. However, as these units inevitably decline in efficiency, facility owners and managers are faced with a critical decision: upgrade to more modern induction units or embark on an extensive, costly renovation project to overhaul the entire HVAC system. While both options have merit, many are opting for the lower capital costs and relative simplicity of replacing existing induction units with modernized versions that are quieter and more efficient due to recent advances in design. Others have no choice, given the limitations of space within the existing structure that preclude installation of additional air handlers or extensive ductwork required with all-air systems. The Renaissance of Induction TechnologyInduction-based HVAC technology is enjoying a renaissance that is largely attributed to the recent interest in “chilled beam” systems. Although traditionally installed in ceilings, chilled beams can also be installed in walls, floors and soffits. Induction systems work by forcing primary (outside) air supplied by central air handlers through specialized nozzles in individual units located in each room or space. By doing so, a “free jet” flow of air is created that induces the secondary air inside the room to also be drawn into the unit, often around 4 times the volume of the primary air. Now at a much higher combined CFM, the secondary air (after flowing through a heat exchanger where it is cooled or heated) is mixed with the primary air. This is accomplished using hot or cold water, which is why these are often referred to as air-water systems. Hospital UpgradesOriginally built in 1972, Greenville Memorial Hospital, the flagship hospital of the Greenville Health System (GHS), was still operating 322 induction units in 267 patient rooms and support spaces. Given that the units were 45 years old, the hospital’s Engineering and Facilities Development teams felt it was time for an upgrade to a newer more efficient alternative. “Although the induction units had been well maintained, and had operated well for 45 years, they were operating at less than full capacity,” says Curt Hall, P.E. principal engineer for Facilities Development at Greenville Health System (GHS). GHS, an academic health center with seven inpatient hospitals and more than 100 outpatient facilities and affiliated physician practices, has a footprint that stretches out over approximately six-million square-feet in over seven counties. According to Hall, the Facilities Development group oversees capital projects, new construction, renovations, moves, and acquisition of facilities. For the Greenville Memorial Hospital project, Hall says the engineering group discussed several alternatives, including a central overhead air system, and fan coil units. However, these would have required installing new air handling units, extensive ductwork changes, and other utility system alterations. All required additional space the hospital did not have and so were quickly ruled out. “We ended up deciding to stay with the induction units,” says Hall. “The decision was driven by the structure of the existing building and what it would allow us to do.” Hall says the engineering group also wanted to take advantage of recent improvements in nozzle design, electronic damper controls (EDC) and other features in modern induction units that can reduce operating costs and provide better air flow distribution. An additional motivation was to reduce energy costs associated with the building’s central air handlers, which were being run at higher pressures to deliver the primary air to the aging induction units. After careful consideration, the engineering group decided to embark on a project to replace the 322 existing units. The project is being completed in increments, with a priority placed on patient rooms, as rooms become available. On average, the conversion takes two days per room to complete. Induction SystemsThe first step was to identify the source of the induction units. For this, Hall contacted the local Trane office. The original 1972 induction units were Trane models. However, the company no longer offers induction units, so the local rep instead recommended an alternative from LTG. Founded in 1924, LTG has been a leader in induction-based HVAC systems for more than 90 years. The company’s U.S. operation is based in Spartanburg, South Carolina, with primary headquarters located in Stuttgart, Germany. LTG’s induction units and chilled beams feature many advantages, such as high cooling and heating capacities, low sound levels, long service life and low maintenance requirements. LTG’s induction units are extremely energy-efficient and can be operated in three different operating and flow modes using the company’s SmartFlow technology. This includes normal mixed/displacement air flow operation, pure displacement, and a variation for rooms with higher occupancy levels (for example, conference rooms) and a “boost mode” for rapid temperature adjustment after a long weekend, etc. Having identified the correct units, Hall and his team began the project. To date, over 90 of the new induction units have been installed, and already there have been noticeable benefits. To start, the new wall units are providing 300-400 CFM of air, up approximately 35% from the previous units. In addition, the more efficient units reduced the workload on the two relatively new primary air handlers that had been installed in 2013. Although both were capable of a fairly high discharge pressure, operating at 7-8 inches of pressure, they also consume more energy at the higher pressures. “We won’t see the full benefits until we replace them all, but with a third of the units installed, we have been able to reduce the pressure on each of our air handler units by 1-2 inches of pressure,” says Hall. Hall is also impressed with the ultra-low sound levels at which the units operate. “The new units deliver a higher air change rate, and they do it quietly,”

Commercial Property Bathroom Remodeling Challenges Facing General Contractors Commercial Property Bathroom Remodeling Challenges Facing General Contractors Selecting experts that specialize in multiple-unit remodels can save on costs while addressing concerns over occupant disruption and speed of project completion Remodeling commercial bathrooms in places like university and college dormitories, public housing, hotels, and in assisted and long-term living facilities involve many complex decisions and steps. For this reason, many general contractors choose to hire sub-contractors for these large-scale projects. Selecting a remodeling partner to handle part of the renovation allows them to focus their time and labor on other aspects of the project. However, choosing the right sub-contractor for large-scale bathroom remodeling projects can be a daunting task, as the wrong choice can directly affect the completion of the project in time and the allocated budget. While bathroom remodeling sub-contractors abound, there are many industry-specific considerations that are best served by those that already have extensive experience working with multiple-unit remodels. These concerns include reducing or eliminating construction noise, and handling noxious odors or dirt/dust than can disrupt the building’s residents. The work must leave a lasting impression while, at the same time, be completed within budget and as quickly as possible to return all bathrooms to service to occupants. In addition, there are economies of scale. Because renovation is typically completed in blocks of bathrooms, installers that regularly service commercial and community housing can often provide better pricing on items – such as acrylic bathtub liners – than those that primarily serve the residential home market. For example, while local companies may charge up to $1000 for an acrylic bathtub liner, a more established company can usually offer half that price. Bathtubs – Replace, Refinish, or RelineBathroom remodeling can involve several projects, but the bathtub is always a key component. When it comes to updating a worn-out bathtub, three options are available, all varying in cost, labor, and potential for guest disturbance: replacing, refinishing, and relining. Replacing an old bathtub is an expensive, labor intensive and time consuming project that often involves demolition and damage to the surrounding walls and floor finishes. Water supply lines and pipes may also need replumbing. For all these reasons, bathtub replacement is rarely an option. Kelly Bennett, a general contractor who recently was the project manager responsible for the complete renovation of a 3-story dormitory for the Department of Homeland Security, including 78 bathrooms, understands why bathtub replacement usually is the last option to consider. “If you can remodel a bathtub without having to demolish all the existing plumbing, you’re going to save a lot of time, especially on a large-scale project like this one.” Bennett explains that replacing a bathtub, especially one with ceramic tiles installed on the wall surrounds, is not cost effective because of the high rebuilding cost. In addition, replacing a bathtub can take several days and can be extremely noisy and dusty, often leading to complaints from building residents. A second option involves the refinishing, or re-glazing, of the existing bathtub. The process includes sanding the current coating, filling chips with epoxy, followed by coating and polishing. While this option costs less than a full replacement, it can take several days to complete. In addition, although re-glazed bathtubs look beautiful, the finish may only last a few years as it can get scratched easily. Another downside is the obnoxious odors released during application. Even with all the proper processes and ventilation, the smell can linger for several days. The third option is to use an acrylic bathtub liner installed on top of the existing bathtub, therefore creating a new bathtub surface that can last for decades. Made from durable materials, acrylic bathtub liners feature high gloss, minimal porosity, and excellent scratch resistance – all of which simplifies cleaning. Installation is a critical aspect with any acrylic bathtub liner. Some manufacturers, such as American Bath Remodeling, have developed their own proprietary and patented installation process to ensure a complete, watertight fit. The Scottsdale, Arizona-based company has been serving the hospitality, commercial and community housing industries for almost 40 years and has remodeled more than a million bathrooms over that span. Kelly Bennett explains that, for the large-scale bathtub remodeling project he was involved with, using American Bath acrylic bathtub liners made the process a lot simpler and faster. “The installation went very well overall,” says Bennett. “The installing team put the bathtub liners right over the existing bathtubs and the ceramic tiles on the wall surrounds. I’d seen acrylic bathtub liners before but this was the first time I used them.” “I was very impressed with their finish and how great they look,” adds Bennett. “After completion, the government was very pleased with the material choice, the pricing, and the installation.” Because the acrylic bathtub liner comes pre-fitted, installation takes less than two hours. With no drying time required, the bathtub can be used almost immediately after installation. Of all the options, relining a bathtub is the least disruptive and the fastest solution to bathtub remodeling. This type of acrylic bathtub liners is very durable, easy to clean and maintain, and can last for several decades before it needs replacing. Wall SurroundsWall surrounds are another remodeling option. Manufactured from non-porous and stain resistant DuraBath® SSP, cultured marble and even granite, wall surrounds are available in many color and pattern options. Installed right over existing walls, including ceramic tile, this is an excellent option for swift installation with little down time or resident disruption. Acrylic wall surrounds can be installed at an even faster rate than the acrylic bathtub liners, up to 10 a day. Made of durable material, they too can last for decades and are easy to clean. Before starting any remodeling project, it is always a good idea to ask others for references and inquire about how much they like the products and the installer. When possible, a visit to look at remodeled bathrooms is also beneficial. Bennett explains that product recommendations are key to the success

Stone Deck Market Opens Up for Contractors Stone Deck Market Opens Up for Contractors Proven installation system opens up market for elevated stone decks and patios, balconies and stairs For years, decks, elevated patios and balconies have been popular choices for homeowners when designing or remodeling their outside living spaces. However, until recently, decking options have been limited primarily to wood or composite materials. Natural stone, pavers and tile – while aesthetically appealing – were simply too heavy and difficult to install on traditional wood joist framing. Fortunately, a new durable, plastic polymer grid system is facilitating the installation of stone up to 3” thick on elevated surfaces. The system, which is designed to support the structural load across a 16 inch on center span, effectively opens up the entire range of stone options for elevated surfaces to include the use of natural stone pavers, travertine, pavers, slate, marble, and tile. “With traditional deck materials, it was nearly impossible to use stone on any elevated surface,” explains general contractor Jim Richardson of Richardson Brothers Construction & Demolition, located in Kendall, New York. “I wanted to offer stone decks to my customers, but any underlayment would have trapped moisture. Plus, the joist system would have to be significantly reinforced to support the weight.” According to Richardson, whose company builds and remodels high-end, custom homes, many of his customers are naturally attracted to stone because it adds substantial value to their homes and increases the aesthetic appeal of the property, while requiring little maintenance. “In my opinion, no composite deck can compare to the beauty of a stone deck,” Richardson adds. “There’s something about the stone that adds style and class and just feels solid.” The weather in the upstate New York area also can dictate the use of elevated surfaces for non-deck areas. Due to freezing and thaws in the region, installing stone directly on the ground can have unexpected consequences. “Even with thorough base preparation, the freezing ground, frequent thaws and ground settling make it very difficult to install stone on the ground,” Richardson explains. “As the years pass, pavers tend to heave up and down, requiring further upkeep and maintenance.” Instead, by elevating the stone, “there is no more heaving, and the grass doesn’t grow between the pavers,” says Richardson. Richardson adds that the installation of a stone deck with Silca Grates is comparable in cost to traditional wood or composite decks, depending on the type of stone used. “When you compare by square footage, the labor and material for installation, the costs for stone decks are very similar to wood or composite decks,” says Richardson. Silca SystemDesigned and manufactured by Sare Plastics, a custom injection molding operation, the Silca System is a deck inlay subflooring grid that can be used on new decks, as well as for retrofit applications. Based on the hexagonally structure of beehives and manufactured from engineered polymers into 1 ½”-thick grids, the Silca Grates ensure a structural surface for natural stone and manufactured pavers. The system is certified to meet building standards by the ICC (International Code Council). The Silca Grates are fastened to the deck joists 16 inches on center using four 3-inch deck screws coated for pressure treated lumber. The grates can easily be cut to any length or contour using a circular, table or reciprocating saw. “I had never seen anything like it before, but I was amazed at how easy it was to cut and install to match the shape of any elevated structure,” says Richardson. “I can use it to build anything my customer’s desire using stone, slate, or bricks – including two-story decks, two or three-tier decks, stairs. The possibilities are unlimited.” Richardson adds that the system can even accommodate the use of sand, whether as foundation to even out irregular stone or polymeric between pavers, by first installing several layers of non-woven textile on the installed Silca Grates. The system can also be installed by homeowners as a DIY project. Mark Batz, a homeowner in Sherwood, Oregon, was looking to replace a well-worn 25-year-old cedar deck. Recurring pressure washing and mandatory sealer treatments every few years were taking its toll on Batz, who at 62 years old, was looking forward to relaxing on his deck rather than maintaining it. This is a common complaint with wood decks, which can warp, crack, distort, split, fade, and promote mold and mildew. To maintain decks, homeowners must seal the wood on an annual or semi-annual basis, along with replacing broken screws and individual boards.So when Batz came across a local contractor looking to discard several truckloads of used pavers and sand that belonged to them from a recent municipal project, he decided to use the material to install two ground level patios in his backyard.His next idea was to remodel his elevated wood deck as well. After conducting some internet research on “elevated stone or paver decks,” he discovered the Silca System. According to Batz, he purchased the product and then installed the pavers on the grates with the help of a contractor friend that also assisted in obtaining the required permits for the project. He then utilized the remaining pavers and the Silca grates on some stairs and even created a hardscape pathway to match the deck. Batz says the Silca grates were easy to work with despite some intricate deck features. “I had to create very specific shapes to fit several octagonal breakfast nooks,” explains Batz. “We used a circular saw with a blade for plastic and the grates cut like butter. They were so easy to install.” Batz is extremely pleased with the result and has already recommended the system to others. “I recommend [the Silca System] for anyone that is trying to build an outdoor surface elevated above ground. Even the inspector said he had never seen an elevated stone deck before, and he was impressed.” For more information, call Silca Systems at (330) 821-1585 or visit www.silcasystem.com.Silca is located at 14600 Commerce Street NE,

Power Tool Displays: Enhancing Interactivity, Preventing Theft Power Tool Displays: Enhancing Interactivity, Preventing Theft New options promote customer interaction and deter theft with cordless and corded tools For retailers of power tools like electric drills, grinders, sanders and reciprocating saws, the customer’s retail experience is just as important as loss prevention. Allowing customers to interact with the product on display by physically handling and testing its weight, heft, and ergonomics can be crucial in a customer’s purchasing decision. Electronic loss prevention devices, which typically involve an alarm console, sensors, and related accessories, are the ideal way to display this type of merchandise and protect against theft. Now, as retailers face competitive pressure to reduce costs and staffing, a greater array of standard and custom options is further improving this category’s appeal in the industry. “Our focus is on finding the perfect balance of helping our retailers best sell and merchandise their products with minimal theft,” says Teri Tapella, Senior Manager of Security Operations at Ace Hardware, the world’s largest retailer-owned hardware cooperative, comprised of more than 5,000 stores in over 60 countries. “This requires letting customers touch, feel, and handle power tool display models while fully protecting them.” According to Tapella, Ace Hardware’s retail stores are independently owned and operated by local entrepreneurs. “From a retail security standpoint, we operate as consultants for our retailers and help them implement best practices to mitigate losses within their stores,” she says. Tapella warns that theft is a problem with power tool displays, including removable rechargeable batteries, and that simple tethering alone seldom resolves the issue. “While store owners can use wire from their own store as security cable, I caution them that any thief can cut it with wire snips found in store a few aisles down,” says Tapella. “That’s why having a second layer of protection like an electronic alarm is essential.” As a solution, Ace Hardware vets and maintains a preferred vendor of loss prevention systems. From the preferred vendor list, Tapella often recommends various units from Se-Kure Controls, a Franklin Park, Illinois-based manufacturer of retail product security devices. Tapella says that the security product selected most often to prevent the theft of displayed power tools is a local alarming system with an electric strip that easily conceals behind or under pegboard. The devices can be connected by cords in a “daisy chain” fashion to allow use at adjacent power tool displays. Multiple security tethers can wrap around or attach directly to each power tool on display. She points out that a number of features in such systems can help to enhance theft prevention in hardware stores. “Se-Kure’s system has local backup battery power, for instance, so if we lose store power, we retain alarm capability,” says Tapella. “The alarm is shut off with a key, which makes it more difficult for thieves to disable it.” One such system operates with battery life of up to 16 months, and if the alarm is triggered, battery power can sustain a continuous alarm for almost seven days. For greater security, it incorporates a “visual memory” that keeps the system’s LEDs flashing until the tampered sensor is identified and corrected. It also has a “Where-It’s-At” option that flashes a light at the top of the display to help employees locate the source of the alarm. Tapella says that attention should also be paid to the types of tether options used. “We find several of Se-Kure’s tether options helpful,” says Tapella. “One simply loops around the power tool’s handle, and if the tether is cut, the system triggers an alarm because it interrupts electrical flow through the tether.” However, according to Tapella, certain items like removable battery packs for cordless power tools cannot be protected with a simple tether because there is no handle to loop it through or around. In such cases, the company offers an option for tethers with dual sensors that Tapella appreciates. “With the dual sensor approach, one tether secures the body of the power tool, and an accompanying tether has an adhesive piece with a sensor alarm on it as well,” says Tapella. “The adhesive attaches to the battery, so if the battery is removed the sensor triggers and the alarm is set off. This can help prevent the theft of any displayed power tools, as well as valuable accessories like lithium batteries.” Another benefit of such an approach is that it preserves the ability to sell display models without damaging them, according to Tapella. In contrast, other approaches, such as those that drill a hole into the product to run a security cable through it, or those that cut off power cords, can render display models unsaleable. To protect corded display merchandise such as drills and sanders from theft, another approach enables securing any corded electrical device by locking the power cord in a power cord lockbox, opened by a key. “As consultants, we can recommend best practices to follow for retail security, but ultimately it is up to the store owners to decide what makes the most sense to them,” concludes Tapella. “Fortunately, there are a range of effective theft prevention options that enable customer interactivity with the hardware tools on display.” For more info, call 800-250-9260 toll free; fax: 847-288-9999; email info@se-kure.com; visit www.se-kure.com; write to Se-Kure Controls, Inc., 3714 Runge St., Franklin Park, IL 60131, USA.

A More “Permanent” Solution to Protecting Carbon Steel Structures from Corrosion A More “Permanent” Solution to Protecting Carbon Steel Structures from Corrosion Innovative coating prevents corrosion of steel structures and appurtenances exposed to standing water, high humidity common in water treatment operations In water treatment operations, which include the plant itself as well as the infrastructure required to collect and distribute water from sources such as aqueducts, reservoirs, lakes and rivers, the wet, high humidity environment can wreak havoc on steel structures and appurtenances such as pumps, piping, pipe supports and other critical equipment. Since corrosion can cause leaks or premature failure of equipment, maintenance personnel are often tasked with monitoring, repairing or re-coating carbon steel items as needed. However, these are little more than temporary solutions that last a few years at best and with equipment scattered in various locations over hundreds of miles, sending staff out regularly is both impractical and expensive. Fortunately, there is a new type of coating that promises to deliver a more permanent solution for water treatment operations. Unlike traditional coatings, the product bonds best with corroded surfaces – so much so that flash rust is often intentionally allowed to form prior to application – to create an alloy barrier that can prevent corrosion for decades. The coating is not only NSF safe for use with water, but can be applied to rusted equipment while it is in service and is safe for application in underground vaults or other enclosed structures. Controlling Corrosion“The total annual direct cost of corrosion for drinking water and sewer systems is $36 billion, which includes the costs of replacing aging infrastructure, lost water from unaccounted-for leaks, corrosion inhibitors, internal mortar linings, external coatings, and cathodic protection,” states the NACE International report Corrosion Costs and Preventive Strategies in the United States. The San Diego County Water Authority, an independent public agency that provides a safe, reliable supply of water to 24 member agencies serving the San Diego, CA region’s 3.3 million residents, sought to improve its anti-corrosion maintenance program. The agency owns and operates extensive infrastructure including about 310 miles of pipeline and 3,000 mechanical units that move the water through the pipeline system. Much of the Water Authority’s aqueduct system relies on the use of carbon steel appurtenances in underground vaults, which are often subjected to high levels of moisture and, at times, submersion in standing water. The agency spends significant resources each year attempting to prevent these steel assets from corroding. To address these issues the Water Authority turned to EonCoat®, a spray applied inorganic primer from the Raleigh, North Carolina based company of the same name. The primer is actually a Chemically Bonded Phosphate Ceramic (CBPC), one of the first of a new category of coatings designed to stop corrosion, ease application, and reduce downtime. In contrast to traditional polymer and zinc coating that sit on top of the steel substrate, the corrosion resistant CBPC primer bonds through a chemical reaction with the substrate and slight surface oxidation actually improves the reaction. When applied to carbon steel, an alloy of stable oxides is formed that will no longer react with the environment and will protect the steel from corrosion. This corrosion barrier is covered by a ceramic layer that resists corrosion, water, abrasion, impact, chemicals, fire, and temperatures up to 400 °F. The double layer of protection – the alloy layer and the ceramic layer – makes it impossible for corrosion promoters like oxygen and humidity to get beneath the coating. “We pride ourselves on being ahead of the curve for all types of technology…includ[ing] the ever-changing coating industry,” says Daryl Akioka, the Water Authority’s project manager for the coating application. “Although most of our assets are underground, it has been a challenge to get proper protection for our above ground appurtenances too. We are hopeful that EonCoat can supply a solution to aggressive maintenance schedules and annual recoating of problematic appurtenances.” In the Water Authority project, the agency used a planned outage on part of their aqueduct system to apply the CBPC primer to seven carbon steel mechanical appurtenances, including a 12-inch blow off, 36-inch turnout pipe elbow, two 8-inch pump wells, and three 10-inch air release valve assemblies. The appurtenances were removed from their below grade vaults and transported to a blasting and coatings facility, where they were degreased and blasted to a NACE 3 / SSPC-SP 6 level, and allowed to flash rust. With traditional industrial coatings, a more labor intensive, time consuming, near white metal blast cleaning (NACE 2 / SSPC-SP 10) is typically required to prepare the surface. EonCoat, which previously achieved NSF certification and won the NACE 2015 Corrosion Innovation of the Year Award in the coatings and linings corrosion control category, was then spray applied at a coating thickness of 20 to 25 mils. Typically, a topcoat can be applied within one hour of applying the CBPC primer due to its rapid drying and curing time. Because it rained during several days of the project, resulting in high humidity in the spray area, the primer was allowed to cure for twice the time – two hours – before the topcoat was applied. In contrast, for standard three-part coating systems the cure time can be days between coats, depending on the product. The equipment was then transported back to the underground vault, reinstalled and successfully returned to service by the Water Authority. Application of the CBPC primer is now being considered for a number of carbon steel in service structures by various water authorities around the country. Since the CBPC primer is inorganic and non-toxic, there are no VOCs, no HAPs and no odor involved. This means the water soluble, non-flammable primer can be safely applied in vaults and other confined spaces. Although CBPC coatings are relatively new in municipal water applications, their use will only grow as word spreads about how they can inhibit carbon steel corrosion for decades as well as reduce premature maintenance and appurtenance replacement. For

The High Cost of Exposing Lawn and Landscape Workers to Chemicals at Point of Use The High Cost of Exposing Lawn and Landscape Workers to Chemicals at Point of Use The tip-and-pour method, as well as poorly designed pumps, can expose workers to injury and companies to significant financial losses Lawn care, landscape, golf course, and nursery handlers and applicators often transfer potentially hazardous chemicals and concentrates such as herbicides, insecticides, adjuvants, and fungicides, from large drums into smaller containers or mix tanks. This transfer process can have serious consequences if manual “tip-and-pour” techniques or poorly designed pumps are used. In fact, each year 1,800-3,000 preventable occupational incidents involving pesticide exposure are reported. Keeping workers safe is not just a best management practice – it is the law. The federal Worker Protection Standard (WPS) was revised in 2015 and now provides a greater focus on reducing pesticide exposures. A closed system of transferring chemicals reduces unnecessary exposures by providing controlled delivery of chemical products without fear of worker exposure, over-pouring, spilling, or releasing vapors. Many of the revisions became effective this January. “Beyond workers compensation issues related to exposure, there can be other huge potential liabilities: Environmental Protection Agency (federal) or state regulatory fines, as well as clean-up or remediation costs,” says Kerry Richards, Ph.D., President Elect of the American Association of Pesticide Safety Educators and former Director of Penn State’s Pesticide Safety Education Program. “This is particularly true if a pesticide gets into a water source, kills fish, or contaminates drinking water.” According to Richards, the direct and indirect costs of a pesticide spill or injury can be substantial, not the least of which is the loss of wasted chemicals. “Pesticides, particularly newer concentrated formulations, are very expensive so spilling a few ounces could cost you several hundred dollars in lost product during a single transfer,” says Richards. Although a number of pump types exist for chemical transfer (rotary, siphon, lever-action, piston and electric), most are not engineered as a sealed, contained system. In addition, these pumps can have seals that leak, are known to wear out quickly, and can be difficult to operate, making precise volume control and dispensing difficult. In contrast, closed systems can dramatically improve the safety and efficiency of chemical transfer, as well as prevent the spillage or loss of valuable chemicals or concentrated formulations. “The availability of new technology that creates a closed or sealed system is ideal for handling pesticides or other dangerous chemicals, and should become a best management practice,” suggests Richards. “With such devices, for example GoatThroat Pumps, pesticide handlers can maintain a controlled containment from one vessel to another and significantly reduce any potential for exposure or spill.” Small, versatile, hand-operated pressure pumps, such as those manufactured by GoatThroat Pumps, are engineered to work as a system which can be either closed or sealed. The pumps can be used for the safe transfer of over 1400 industrial chemicals, including the most aggressive pesticides. These pumps function essentially like a beer tap. The operator attaches the pump, presses the plunger several times to build up a low amount of internal pressure, and then dispenses the liquid. The device is configured to provide precise control over the fluid delivery, from slow (1ML/ 1 oz.) up to 4.5 gallons per minute, depending on viscosity, and are safe to use with virtually any container from 2-gallon jugs to 55-gallon drums. Golf Resort Adopts “Best Practice” Pump SystemsMike Cocino, assistant superintendent of Seaview Golf Resort in Galloway, NJ, sought a safer, more efficient way to transfer liquid fertilizers, wetting agents, biostimulants, and other plant growth regulators from 55 gallon drums to measuring containers. These would, in turn, be transferred to mix tanks ranging in size from 1 gallon hand pumps to 300 gallon sprayers. Additionally, according to Cocino, sliding the heavy drums off of pallets with a dolly, and then tipping and pouring the drums was challenging, particularly in areas with limited storage. “Drums can roll or fall, and you do not want to lose control of an entire drum,” says Cocino. “When tipping a drum, it’s difficult to pour out the right amount and easy to over-pour or splash some of the contents out.” Cocino adds that getting to the needed drum typically required his staff had to move a few other drums out of the way, which was a laborious process. To address these issues, Cocino purchased three GoatThroat Pumps and was happy with the results for a number of reasons. “Safety is a huge priority for us, and with the sealed pumps we’re able to safely pump whatever product we need without moving or tipping any barrels,’” says Cocino. “The barrels stay safely in place, upright on their pallets, which is definitely a ‘back saver.’ Because of this, we’ve eliminated any issues of spillage or related cleanup.” Cocino estimates that by avoiding the need to move the barrels, tip and pour product, and clean up any potential spills, his operation saves at least 50 hours of labor annually. “The closed sealed pumps also allow my staff to safely and completely empty the contents of each barrel,” says Cocino. Previously, tipping and pouring left a significant amount of product at the bottom of each barrel because it was hard to remove. In addition, he says that precise control of product from the pumps enables exact filling of the measuring container to desired fill lines. This provides better, more consistent results in the mix tank. “Our golf maintenance operation is safer, cleaner, and more efficient with our GoatThroat Pumps,” concludes Cocino. “Any golf course, lawn care, landscape, or growing operation that requires the safe transfer of liquid chemicals should look into them.” Safe Chemical Handling at Lancaster FarmsWhen Lancaster Farms, a wholesale container plant nursery serving the Mid-Atlantic and New England regions, required a lower pH to adjust its well water for a pesticide spray application, it had to transfer sulfuric acid to buffer the spray water. According to Shawn Jones, Lancaster Farms’

Simple, Effective Crosshole Deburring of Complex Metal Parts Simple, Effective Crosshole Deburring of Complex Metal Parts By integrating flexible hones in the machining process, complex parts with cross-drilled holes and other difficult-to-access features can be deburred in house, at less cost   In automated machining, removal of burrs and sharp edges in cross-drilled holes and other difficult-to-access areas such as undercuts, grooves, slots, or internal holes can be tedious and time consuming. One particular challenge is deburring the intersection of cross-drilled holes frequently found in engine and transmission components. Despite the challenges, the removal of burrs from the production process is an absolute must for high quality, precision parts. In many applications, cross-drilled holes act as conduits for fluids, lubricants and gases. Failing to remove burrs can cause blockage of these critical passages or create turbulence in the flow. Burrs can also lead to part misalignments, affect dimensional tolerances, and limit the overall efficiency of machined components. “Getting rid of burrs is really important because if there is any loose material that gets dislodged when the product is in use, it can cause major problems,” says Anthony Scott, Lead Machinist at Orange Vise Company, a manufacturer of machine vises and quick change fixturing components. Although there are many techniques for deburring internal passages at cross-holes, the majority require sending out parts or investing in equipment to complete the work in-house that can cost tens of thousands of dollars. These options, which include thermal, abrasive flow, electrochemical, and high-pressure water, effectively remove excess material but they also build time into the manufacturing process and add to costs. The more ideal option, however, for many machining operations is to integrate deburring into the automated process with a simple, effective crosshole deburring tool such as the Flex-Hone from Brush Research Manufacturing (BRM). By doing so, operators can speed up the manufacturing process and ensure uniform quality for precision parts. According to Scott, flexible hones are ideal because it is a cost-effective solution to smooth edges and produce a blended radius for crosshole deburring. “It is really about accessibility, because there aren’t really any other tools that can do what a Flex-Hone can,” says Scott. “Whether it is internal grooves or multiple cross-holes, there is really no way to reach those areas with any sort of other tool.” For engineers in the automotive, aerospace, manufacturing and machining industries, the ball-style hone is a highly specialized abrasive tool that is instantly recognizable by its unique appearance. Characterized by the small, abrasive globules that are permanently mounted to flexible filaments, the product is a flexible, low cost tool utilized for sophisticated surfacing, deburring and edge-blending. Available in sizes ranging from very small diameter hones (4mm) to those up to 36 inches or more in diameter (a size appropriate for large engine cylinder bores), these deburring tools can be custom designed to the size, shape and abrasive grit to fit any application’s needs. “I used the Flex-Hone quite a bit when I was working in aerospace,” explains Ken Spaulding of Zodiac Engineering, a contract manufacturer in California. “We did a lot of parts that involved tubes with multiple crossholes and slots. Getting inside there to reach the burrs, particularly if the walls were thick, is extremely difficult.” With a background in aerospace parts as well as mold making, Spaulding is currently focused on creating products of his own design, such as high end pocket knives and cycling components for BMX, road and mountain bikes. He also continues to perform contract manufacturing work. Spaulding particularly appreciates how the flexible hone’s abrasive globules each have independent suspension that is self-centering, self-aligning to the bore, and self-compensating for wear, all of which facilitate close-tolerance finishing work. “The hone conforms to whatever you are working with, even if it’s irregular,” says Spaulding. “For example if the back side of the part is not flat or not on consistent level plane in z, the tool is flexible enough to still remove any burrs.” For best results, the deburring tool is typically rotated into the main bore into which the crossholes break. After a few clockwise strokes, the tool is removed and the spindle reversed to rotate and stroke the flexible hone in a counterclockwise direction for a few more strokes. The forward and reverse rotation creates a symmetrical deburring pattern. Coolant should be used to keep metal cuttings and deburred metal in suspension. According to Orange Vise’s Scott, although the Flex-Hone is often used with automated production equipment it can also be used for secondary deburring options offline as needed. “The tool can be used in CNC machines and also with a cordless drill,” says Scott. “So, if you manage to deburr 90% of the holes in a machine, but have a few left you can’t access easily, you can use it with a handheld drill and maintain the uniformity in surface finish and process.” Additional customization from BRM in a variety of shapes is also possible to meet the requirements of non-traditional applications. This includes spherical-end configurations, stepped or multi-diameter configurations for double diameters and counter-bores, tapered or cone shapes, segmented shapes, or combining Flex-Hone globules with other filament materials. For more information, contact Brush Research Manufacturing, Brush Research Mfg. Co., Inc., 4642 Floral Drive, Los Angeles, CA 90022; Phone: (323) 261-2193; Fax: (323) 268-6587; email: info@brushresearch.com or visit the web site: www.brushresearch.com

Simplifying Vehicle Maintenance and Repair Shop Spill Clean-Up Simplifying Vehicle Maintenance and Repair Shop Spill Clean-Up New products can absorb oil spills quickly with no dangerous dust, slippery residue, or heavy lifting Vehicle maintenance departments and repair shop floors always seem to end up as a huge mess due to spills or leaks of oil, grease, brake fluid, transmission fluid etc., creating a dangerous slip and fall hazard and interrupting work flow until it is cleaned up. While cleaning up such messes traditionally involves using clay type absorbents or a mop and bucket, these methods actually do an unsatisfactory, inefficient job. Not only is clay heavy, but it is extremely dusty when dry and the airborne dust can be dangerous, even cancer causing, if inhaled. Clay absorbents can also leave a hard-to-remove residue that typically must be scrubbed with secondary cleaning methods, including a mop and bucket. But this usually leaves slippery wet spots to dry, followed by disposal of the oily water, which may be regulated. “Absorbents like clay can become sticky when used to clean up spills or leaks on the shop floor,” says Anthony Eid, owner of Perris Auto Repair, a repair shop in Perris, California. “Mopping can make a mess if you push spilled oil and clay absorbents around. It is not effective and people can slip, fall, and get hurt until any spill is fully cleaned up and the floor is dry.” Fortunately, for shop safety and production managers who know what to look for, cleaning up the inevitable messy spills on the floor no longer has to be difficult or time consuming. Now a new breed of commercial absorbents is promising to simplify spill clean up safely and quickly so work can resume with no hazardous dust, slick residue, or back breaking lifting of heavy bagged absorbents. Dustless Cleaning ProductsCommonly used cleaning absorbents such as clay or diatomaceous earth are extremely dusty in their natural form, and can be hazardous when inhaled. While water can be added to reduce dust, as soon as the water evaporates (when a package is left open for instance), they return to their very dusty original state. “Products like clay can dust up unless you wet them down, and they get dusty when they dry out,” says Eid. “We want to avoid any dangerous dust in our enclosed, indoor shop environment.” Many such absorbents, like clay and diatomaceous earth, contain crystalline silica, which is listed by the World Health Organization as a Group 1 carcinogen, the same category as asbestos. If inhaled, crystalline silica can also cause silicosis, a debilitating and sometimes fatal lung disease. OSHA recommends “replacing crystalline silica materials with safer substitutes, whenever possible.” As a solution, a growing number of vehicle maintenance and repair shop managers are turning to safer “dustless” alternatives. One example, a cleaning absorbent called Eco-Absorb, which is made from an all-natural, non-toxic earth compound and certified by NSF International for its safety around humans and food, is permanently “dustless” without adding water. Because of this, it can be used safely without worry of inhalation, and will remain dust-free even when exposed to the open air indefinitely. “We breathe easier because Eco-Absorb is dustless without having to add water,” says Eid. “It goes down dry, and we use it to clean up any spills such as oil, coolant, transmission fluid, or even fuels.” While clay is a poor absorbent (it is mostly coated by the spill and absorbs it quite slowly), better absorbents act much faster. This expedites the clean up, and allows personnel to get right back to work. The “dustless” absorbent, for instance, picks up spills in a quarter of the time compared to clay. “We found that the eco absorbent soaks up spills several times faster than clay, and does a better job of clean up in much smaller quantities,” says Eid. No “Slippery” ResidueTo protect shop mechanics and other workers from slip and fall accidents, which can be costly and carry some liability, managers also need to use a spill clean up product that does not leave water (like mopping) or an unsafe residue. Floors left wet from mopping, of course, remain a slip and fall hazard until completely dry. Absorbents like clay and diatomaceous earth, for their part, leave a residue that requires a secondary cleaning process, and can be slick and remain a hazard when wet. To address these concerns, innovations in spill management technology have eliminated the need to add water to some products, as well as handled the issue of leftover residue. Because all natural absorbents like Eco-Absorb, for instance, are applied dry they reduce the risk of slip and fall liability. As a best management practice, such absorbents can be applied dry to contain and clean up oil or other spill and leave no residue. When placed around a spill, the absorbent acts like a sponge. It quickly absorbs the spill material and binds to it. This makes it easy to sweep up the substance along with the absorbent into a dustpan, to dispose of in a proper solid waste receptacle. “When we use the eco absorbent to clean up spills, there is no slippery residue,” says Eid. “It cleans up spills in one step, unlike clay which requires clean up after the clean up to get rid of the sticky material left behind.” No Heavy LiftingAnother issue with spill clean up absorbents like clay and diatomaceous earth is that they are extremely heavy. Because such products have relatively low absorption to weight ratios, a lot of product must be used to clean up spills of any size. As a result, a worker could easily injure himself or herself handling multiple 50 pound bags of clay or diatomaceous earth to clean up a spill. This is another potential worker’s compensation or liability risk. The weight and quantity of absorbent is also an issue when it comes to disposing of it after the spill clean up. To address such issues, innovative absorbents now pack more

Ensuring Urban Oasis Remains Watertight Ensuring Urban Oasis Remains Watertight Renovations of the famed water features at Fountain Place focuses on waterproofing with seamless, flexible, chemical and UV resistant coatings Fountain Place in Dallas, TX is an architectural wonder known for its “dancing” water gardens at the base of a dramatically sculpted office tower of reflective glass designed by I.M. Pei. However, when it was time for its famed water features to be renovated, the building’s ownership group and primary engineer wanted to be confident that the restoration would be leak proof well beyond the waterproofing materials used in its original construction. While Fountain Place has always been structurally sound, the water garden renovation was complicated by a couple of factors, according to Gary Bennett, Fountain Place’s owners group representative. “The water gardens were originally constructed above a parking garage with thousands of concrete cold joints, using separate pours not really designed to be waterproof,” says Bennett. “The vertical to horizontal concrete components were sealed with various waterproofing products that were not completely designed for the condition in how they were used.” As a solution, they turned to a new breed of seamless, flexible coatings that, used in combination, are designed to prevent water leakage, provide chemical and UV resistance, and enhance aesthetics for decades. Keeping an Oasis Watertight The Fountain Place renovation project consists of nearly two acres of cascading waterfalls, pools, fountains, and elevated walkway pavers, according to John Pierce, Executive Vice President at Mobile Enterprises, a specialty commercial architectural and structural contractor. Mobile Enterprises is responsible for restoring the water gardens including concrete repair, waterproofing, and paver replacement for the entire project. According to Pierce, elastomeric coatings had been primarily used to waterproof Fountain Place’s water features. However, these had deteriorated over time, leading to water leaking into the parking garage below. “The original design used polyurethane based elastomeric coatings over 20 years ago,” says Pierce. “While these have UV resistant topcoats, over time exposure to chlorine in the water as well as outdoor UV rays begin to bake those membranes. They become soft, and chalky. They wear out, become susceptible to substrate movement, and prone to leaks.” Beyond this, the location of the water features presented additional challenges. “The fountains are built over a concrete parking structure that is moving as cars drive around looking for spaces,” says Pierce. “The parking deck’s top slab is made up of pre-cast planks with a topping slab. Because of this, there is movement in the garage structure.” Pierce says that any water feature waterproofing must also accommodate daily and seasonal temperature changes, since this can cause concrete substrate movement, leading to leakage over time too. “Mid Texas summers are hot and winters are cold,” says Pierce. “This will cause water feature concrete expansion as higher temperature water flows over it in summer and contraction as colder water flows over it in winter. Thermal cycling between day and night can also cause some substrate movement as well.” According to Bennett, all the substrate movement was well beyond the original waterproofing products’ capability to maintain constant waterproofing. Despite these challenges, any waterproofing used in Fountain Place’s renovation had to endure concrete substrate movement and still not leak. Pierce says that some of the Fountain Place’s pools above the parking garage had been remediated with a PVC roofing membrane with heat welded seams, but still had leakage issues. “Most waterproofing materials with heat welded seams must remain fully adhered to the substrate,” says Pierce. “However, moisture in the concrete can diminish the membrane’s adhesion, leading to gaps and water leakage. This is one reason that a seamless system is often preferred over a seamed system.” Pierce says that many traditional materials would also not be up to the task of waterproofing. “Materials like plaster, epoxy, or tile would need to have an underlying elastomeric membrane to function because anything rigid would crack and leak,” he says. “Being constantly submerged and not being chemical resistant can also cause problems to the underlying membranes.” Instead of less durable coatings and traditional pool membranes, Fountain Place’s ownership group and primary engineer selected an elastomeric polyurea basecoat and topcoat combination from VersaFlex, a global supplier of high-performance polyurea coatings, liners and joint sealants for a wide variety of architectural design environments. As part of Fountain Place’s restoration, Mobile Enterprises removed water feature materials down to the original structure, as well as paver stones in plaza area walkways. After completing necessary concrete repairs and priming water feature areas, the company sprayed a 60 mil basecoat of VersaFlex FSS 45DC or waterproofing. The spray-applied polyurea basecoat creates a seamless, waterproof, durable protective liner that stops leaks and strengthens the integrity of the entire structure. It exhibits superior physical properties such as high elongation, crack bridging, hardness, and tensile strength to create a robust, resilient, puncture resistant liner. It is also designed to withstand, wide variations of temperature and humidity including decades of freeze-thaw cycling. “The polyurea basecoat provides a seamless, flexible, waterproof membrane system,” says Pierce. “It is flexible enough to accommodate structural garage movement, ground movement, as well as daily or seasonal expansion or contraction due to temperature changes. Anytime you deal with concrete, you deal with cracks, so its crack bridging properties are also important.” On top of this, Mobile Enterprises sprayed a 20 mil topcoat of GelFlex, an aliphatic chemical resistant, UV color stable, 100% solids, polyurea topcoat. “GelFlex bonds seamlessly, tenaciously to the basecoat,” says Pierce. “It provides chemical and UV resistance as well as a high gloss, color stable, aesthetic look designed to last decades.” Together, the polyurea basecoat and topcoat “provide a much tougher, more aesthetic membrane for the long haul than other softer elastomeric coatings,” adds Pierce, who also reinstalled an elevated paver pedestal system at Fountain Place by Wausau. Spraying of the polyurea basecoat and topcoat is achieved with a plural component spray gun connected to a long heated hose and pump machine. Unlike a traditional two-part epoxy topcoat

Enhancing Storage to Accommodate New Product Launch Enhancing Storage to Accommodate New Product Launch Custom pushback rack improves storage density, safety at Hyundai Powertech Hyundai Powertech sought to optimize storage at its Georgia manufacturing facility to make room for additional assembly parts required for an 8-speed transmission product launch. As a main auto parts manufacturer of Hyundai Motor Group, Hyundai Powertech specializes in automotive transmissions. The company manufacturers a full line of transmission parts, from compact to full-size, that fulfill the needs of more than 600,000 transmissions annually. However, with limited warehouse space, the double selective upright rack previously used in the area was insufficient to receive the additional parts, according to Yong Kim, the facility’s Material Department Assistant Manager. Kim turned to Mathand, a turnkey material handling systems integrator out of Georgia, to resolve the issue. Mathand recommended pushback pallet rack from Steel King Industries, a storage system and pallet rack manufacturer. Pushback rack offers up to 90 percent more product storage than selective rack. Unlike static, single-pallet deep selective racks, a dynamic pushback rack system allows storing pallets two to five deep while providing easy access to a variety of different SKUs. Pallets are stored behind each other in a series of nested carts and are loaded from the same side of the system, eliminating separate aisles for each function. Composed of a stable rack along with a series of inclined carts and rails, when one pallet is pulled, the one behind it rolls forward. Since every pushback rack system is made to order, custom requirements such as for weak pallet support, non-standard pallet sizes, and other special pallets can be accommodated. After touring the factory and completing the initial drawings of the new system, an ongoing discussion among the three companies revealed a unique material handling issue that needed to be addressed. “Our 8-speed transmission parts are heavy and very sensitive,” explains Kim. “Most parts are packed in small plastic boxes and stacked on plastic pallets. The pallets arrive strapped down, but our work process involves us unpacking a portion of the parts and then repacking and racking the rest. These partially packed pallets are more susceptible to tipping over, so it is important they are properly secured.” As a solution, Mathand recommended a custom, level cart pushback rack configuration, designed to keep the carts and the unstrapped pallets flat and secure. “We suggested a level pushback cart and a level first pallet position so when the carts are pushed back or ride down the inclined rail slope, the pallets will always remain level,” explains Matt Davis, a Mathand Product Specialist involved with the project. According to Davis, achieving this custom configuration required numerous design iterations in cooperation with Steel King engineers, who provided CAD drawings as needed. “Instead of the cart following the angle of the rail, the front of the cart is raised, so it is taller in front and shorter in the rear,” explains Davis. “On a flat surface, the cart and pallet would seem to be leaning back, but going downhill on the pushback rails they are completely level. This design allows the cart to roll down the rails by gravity without it sloping at an angle.” Because Hyundai Powertech placed a priority on safety, Mathand also worked with Steel King to create custom stops on the cart to prevent double loading of pallets onto the cart. “Now when a forklift operator loads the first pallet position, he cannot set it onto the cart incorrectly at an unsafe angle,” says Davis. “This helps to ensure proper loading and prevents the pallet from potentially tipping over.” For added strength in phase I of the project, SK3000 pallet rack, a rugged bolted rack with structural channel columns, was chosen. Compared to typical racking, the pallet rack constructed of hot-rolled structural channel column with full horizontal-diagonal bracing offers greater frame strength, durability and cross-sectional area. All grade-5 hardware provides greater shear strength, and a heavy 7-gauge wrap-around connector plate ensures a square and plumb installation with a tighter connection and greater moment resistance. According to Davis, four double bays, four levels high, by two deep were constructed for 64 pallet positions of pushback rack in a space constricted area for phase I of the project. “The pushback rack provides double the storage capacity of selective rack, and four times that of floor storage in the same space,” says Davis. Phase II of the project involves creating another 40 bays of pushback rack to provide enough assembly part storage for Hyundai Powertech’s 8-speed transmission product launch. For safety, this uses the same level pushback cart design, but has three levels, with a carton flow pick system on the bottom and two levels of pushback rack on top. However, to save cost, the project customized Hyundai Powertech’s existing SK2000 selective rack, a boltless, closed tubular upright product. Compared to open back roll formed columns, the closed tubular uprights are 44 times more torsion/twist resistant, with 250% greater frontal impact resistance and 68% greater side impact resistance. With Phase II of the project currently underway, Kim is projecting to see significant benefits. “The 40 bays of pushback rack will provide about 31% more storage than double sided selective rack,” says Kim. “In terms of safety and efficiency, forklift operators will only need to load and unload from one side, instead of two, which minimizes forklift travel and potential collision or rack impact.” “Any warehouse that requires greater storage density should consider pushback rack,” concludes Kim. “Customizing it can help with specialized warehouse applications, such as those handling small, sensitive or heavy products.” For more info contact Steel King at 2700 Chamber St., Stevens Point, WI 54481; call 800-826-0203; email: dheemstra@steelking.com or visit the website www.steelking.com.