SUSTAINABILITY IN MANUFACTURING
SUPPLEMENT
Selecting the best technologies and components, and using best practice in design, build and operations, manufacturer can reduce their energy consumption
entry-level pulse valves to energy reducing vacuum generators and more intelligent products, such as totalling flow meters that provide energy consumption monitoring and control.
ACTUATION SYSTEMS FOR REDUCED ENERGY When we have eliminated the inefficiencies leading to the actuator, the last remaining element is the choice of actuator. Clearly this has a significant effect on the amount of energy a machine consumes, too. Two key areas where efficiency gains could easily be
realised come from reduced friction and weight.
8. Reducing friction The lower the friction, the lower the loss of energy and the longer the lifespan, so it’s important to consider the guidance systems that will be selected – for example, plain or recirculating ball bearings, impacting the friction in the guide system to support loads. Festo’s DGSL and DGST pneumatic mini slides move extremely accurately and with minimal friction. In operation, manufacturers need to regularly maintain drive guides to reduce frictional losses.
9. Reducing weight The lower the weight, the less energy is needed to move that weight and sustainability can be improved. A quote from Colin Chapman of Lotus that I’ve always admired is: Simplify, then add lightness. This means consciously and systematically reducing moving mass right from the end effector up through the various rotary and linear axes. Hybrid systems combining pneumatic and electric actuators can often provide the optimum solution. For example, using pneumatics for the grippers and on a primary Z axis saves weight through all subsequent axes. They have a higher force density and lower weight than electric ones.
10. Expert advice Following some simple measures, combined with selecting the best technologies and components, and using best practice in design, build and operations, manufacturers can reduce their energy consumption and carbon usage. This is particularly important with compressed air systems, which are notorious for over-sizing and poor maintenance – both of which can be relatively easily solved. By engaging with experts who fully understand the challenges and solutions faced, manufacturers will be able to considerably improve their sustainability performance.
Festo
www.festo.com/energysaving
EUROPLAZ INVESTS £700,000 INTO ‘GREENING’ ITS MANUFACTURING OPERATIONS
Europlaz, which is committing to becoming the most sustainable healthcare contract manufacturer in the UK, has invested more than £700,000 over the last six years into ‘greening’ its manufacturing operations and making a positive impact on the communities it operates in. As part of this bold move, the company has secured the ISO:14001 environmental accreditation, produces up to 68% of its energy from solar panels, and reinforced its desire to be Net Zero by 2045 – in line with the requirements set by the NHS. Ellie Harrington, sustainability officer at
Europlaz, commented: “We are proud to manufacture products that save lives and want to extend this philosophy by making sure we have a positive Environmental, Social and Governance strategy (ESG) in place. “This got underway six years ago, but
the last twelve months have seen us really accelerate our investment in this area as we can see the difference it is making to our environmental footprint, the wellbeing of our staff and the sectors we operate in.” She continued: “For the first time ever,
we have managed to calculate the carbon footprint of a product we manufacture. TIVA (Total Intravenous Anaesthesia Sets) involves production and two-stage assembly - we’ve completely mapped the process so that we can look at ways where we can minimise waste, reduce energy and ultimately cut the carbon footprint involved. “This is just the start, and we hope to create
the greenest anaesthetist product ever made. We’ve now got another six products we’re looking to do the same for.” The company, which is ISO13485- certified, operates from its state-of- the-art site on The Maltings Industrial Estate in Southminster, near Chelmsford. From here, the
family-run business has invested £4m into creating a world class facility capable of injection moulding, assembly, product validation and access to modern cleanrooms, all certified to ISO Class 7 for the manufacture of Class I, Class II and Class III medical devices.
MEDICAL SECTOR SOLUTIONS Most of its work is focused on helping medical device and healthcare businesses commercialise new technology, with recent success stories featuring a home dialysis machine, a patient friendly and easy-to-use breath operated inhaler and a bio-artificial liver.
The Total Intravenous Anaesthesia set
Harrington concluded: “Sustainability is a win-win. We know we are measuring and refining our production processes so that we can manufacture as green as we can. “It also means we are meeting domestic and
global healthcare standards, and this is already paying off. So far, we believe this approach has resulted in £650,000 of new work that we previously would have been excluded from.”
Europlaz
www.europlaz.co.uk
JULY/AUGUST 2025 DESIGN SOLUTIONS - SUPPLEMENT 31
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