Q: Please briefly explain your role, involvement, and experience with Bulk Materials Handling
Scott Harding (SH): I have an extensive 30-year career covering areas of bulk materials handling, processing, filtration systems, and conveying systems. My membership in the Solid Handling & Process Association (SHAPA) further underscores my commitment to staying updated with industry trends and networking with fellow professionals.
Richard Hemming (RH): I am responsible for ensuring the timely and safe delivery of circa 1,200 tonne of HD resin pellets each month into our four 100-tonne capacity silo tanks onsite, and the effective transition of that raw material into 1.3 million HD plastic milk bottles each day (~40te), as part of an in-house supply operation for a major UK dairy site. The purely mechanical elements of the handling and storage of bulk resin provides multiple challenges, and the successful conversion of that material into finished product requires continual monitoring and human interaction, even in a highly automated environment. I have been the site Operations Manager for 8 years now, and have gained a good understanding of the processes involved at every step of the material and product flow, but am by no means an “expert” and always take the opportunity to develop my knowledge further…I thoroughly enjoyed the seminar at IMechE HQ in 2019 and have used some of my learning from that day with my team, to better understand what we have and how we can optimise our use of the equipment in situ.
Roger Watson (RW): I work for R&B Industrial, a member of SHAPA with expertise in LEV (Local Exhaust Ventilation) and associated filtration systems. For the past 8 years I have been responsible for providing consultancy in DSEAR and Occupational Hygiene. The main bulk solids encountered during this work are:
• dust, chippings or shavings from machining of wood, plastic or metal
• powdered food ingredients (e.g. flour, sugar) or grain
• biomass pellets
• various polymer powders
Howard Wheeler (HW): In the 1980’s I started my career working with conveying/bunkering systems and stacker/reclaimer machinery for coal and limestone in the mining and quarrying markets. Initially for British Coal and Blue Circle Cement. At various stages since then I have continued to work in both areas but more recently in quarrying and cement production with Breedon Cement in Hope.
Q: What is the top challenge facing your industry at present?
SH: The top challenge in our industry right now is undoubtedly the push for net zero emissions. While we are committed to sustainability, this goal often conflicts with the product price point. However, we are actively working to address this by emphasizing the total cost of ownership in our sales efforts, showcasing the long-term benefits that outweigh initial costs. It's a delicate balance, but we're dedicated to finding solutions that align with both environmental goals and economic realities.
RH: Updates in regulations for material usage food packaging applications, and the absolute priority of the safety of people as they handle the raw and re-processing of these materials (including the dust arising from poor granulation of trimmed flash).
RW: Many ‘off the shelf’ products are low-cost, but don’t work effectively or require unrealistic user input to work effectively.
HW: From the perspective of my talk, the dramatic increase in cyber security threats from numerous directions and players, and how it effects operational technology.
Q: How would you say your industry has evolved over the past two years?
SH: Over the past two years, our industry has experienced significant shifts driven by various factors. The impact of COVID-19 brought about challenges and opportunities alike. While supply chain disruptions were a concern, the pandemic accelerated the adoption of technology for remote monitoring and control, enhancing operational efficiency.
Brexit and ongoing globalisation efforts have reshaped our manufacturing landscape. Navigating new trade regulations was a learning curve, but it also prompted us to diversify our supply chain and explore regional partnerships, strengthening our market presence.
The safety of our products has remained a top priority. Concurrently, we've dedicated resources to developing more energy-efficient products. This focus aligns with current and future legislation while also addressing sustainability goals.
In essence, these dynamic shifts have fuelled innovation, collaboration, and a heightened awareness of industry resilience. We're excited to continue driving positive change as we adapt to emerging trends and demands.
RH: Pressure on plastic usage for packaging, reduction of waste, and the update of regulation have all provided many challenges to overcome…plus the Plastic Tax and increased use of post-consumer recycled materials.
RW: There is increased market diversity and profile of ‘Smart’ systems for LEV diagnostics, control, and efficiency.
HW: With respect to cyber security, automation using programmable and connected control systems is becoming universal. Programmable and connected devices are now the norm and all are vulnerable, every such device can be attacked or hacked.
Q: What developments are going on in your industry that may have an impact on the future work of materials handlers?
SH: In our industry, we're witnessing exciting developments that will greatly influence the work of materials handlers. Innovation in sustainability is driving the emergence of new processing techniques for recycling, especially for materials like plastics. The growing focus on achieving net-zero emissions is pushing us to adopt more efficient process plants, aligning with the industry's commitment to environmental responsibility and efficiency. These advancements will shape the future landscape of materials handling, requiring handlers to adapt and stay updated with the evolving sustainable practices and technologies.
RH: Improvement of waste material condition arising after the moulding process (granulation), new players in the UK resin market (food grade HD), minimising the pellet loss during transport and transfer to site equipment (Operation Clean Sweep initiative).
RW: We are developing a fully wireless energy-harvesting damper system to optimize control and efficiency of LEV systems. It will be particularly important in dust-handling systems (e.g. woodworking, food manufacturing) which operate at high duct air velocities. See item 6 at https://www.gov.uk/government/publications/industrial-energy-efficiency-accelerator-ieea/industrial-energy-efficiency-accelerator-phase-4-projects-funded-under-nzip).
HW: Attackers using artificial intelligence will greatly decrease the effectiveness of current defence mechanisms. Those undertaking cyber-attacks are often much more experienced and knowledgeable than those trying to defend operational technology.
Q: What will you be presenting at the ‘Compliance in Bulk Materials Handling’ seminar and how will this benefit participants?
SH: My presentation on ATEX raises a critical point about the uncertainties surrounding safety concerns in hazardous areas. It's clear that end users hold the ultimate responsibility for employee safety within potentially explosive environments, as stipulated by the ATEX directive. The challenge lies in ensuring the safety of hazardous area equipment. The existing ATEX approach places significant reliance on manufacturers' accuracy during certification, which can lead to pitfalls in the process, highlighting the notion that "we don't know what we don't know." The examples I provide reveal issues with current standards, manufacturer conformity assessments, and the lack of awareness among Notified Bodies about the correct EN standards. The fact that non-electrical hazardous area equipment can be produced without independent review or testing underscores the substantial risk faced by end users. This presentation emphasizes the urgent need for robust measures to bridge these gaps and ensure the safety of those operating within hazardous environments.
RH: My aim is to inform the audience about how my site team handle the raw and waste materials necessary for our supply to the largest dairy milk site in Europe, and how we are meeting the challenges of changing legislation and improving people safety within a highly automated manufacturing operation.
RW: I will be presenting on wood dust handling, including the COSHH/DSEAR risks, the technology available to manage them and the relevant standards/guidance (e.g. WIS23, WIS32, EN12779, EN16770). Many of the principles can be applied to other manufacturing activities where the standards and guidance are less developed.
HW: “The Functional Safety Air Gap – how do you know your operational technology underpinning safety is out of the reach to accidental or malicious actors?”
Q: Why is it important for academia and industry to come together at this event and share experiences and project developments?
SH: Compliance in bulk materials handling is a pivotal topic that significantly impacts safety, system efficiencies, and energy savings. It ensures that industry practices adhere to regulations, minimizing risks and enhancing overall operational efficiency. The collaboration between academia and industry at events like this is crucial. Academia brings cutting-edge research and fresh perspectives to the table, while industry offers practical insights and real-world challenges. By sharing experiences and project developments, both sides can learn from each other, leading to innovation and best practices. This collaboration accelerates the adoption of safer, more efficient, and energy-saving technologies and methodologies, benefitting the entire bulk materials handling ecosystem.
RH: The science behind materials and how bulk handling actually works to deliver material of the correct grade and condition is key to maintaining safety of the final product and of the people involved in the process. We have a good site operation to share with the audience, but I am also realistic in that we can improve, maybe in areas we have not yet realised!
RW: Academics will often only have the opportunity to engage with large manufacturers who can afford to sponsor research. There can be a lack of awareness of practices by the many thousands of SMEs in the UK. Consultants and equipment manufacturers can be an important ‘bridge’ between academia and SMEs.
HW: Neither party fully understands the limitations and requirements of cyber security. A layer of protection approach is necessary to keep hackers away from OT devices, together academia and industry can strengthen the required defence.
Compliance in Bulk Materials Handling 2023 will be taking place on 10 October at the Argyll Ruane Engineering Training Centre in Sheffield.
Join this seminar to:
- Gain a broad overview of relevant regulations and compliance applicable to a wide range of bulk handling scenarios
- Hear practical case studies to guide them on compliance and best practice, allowing them to more perform their duties more safely and with reduced environmental impact
- Remain informed of changes to codes and interpretations of codes allowing them to keep up to date with movement in the industry
- Be more aligned with senior industry peers who have more compliance experience which will improve organisational synergy
- Learn best practice to follow which will improve the lifetime of equipment, increasing the value extracted from it and reducing the likelihood of warranty void issues
To book your place, please visit the event website.