2012 - PageSuite

71 Remote monitoring 81 Rugged flexible enclosures 89 Oil contamination

Remote Monitoring 

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Compact Infrared Cameras with On-Board Visual 

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Duct-Pipe Leakage 

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iPad ® not included 

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Because of transmission frequency regulations, these wireless products 

© COPYRIGHT 2012 OMEGA ENGINEERING, INC. ALL RIGHTS RESERVED 

may only be used in the United States, Canada and Europe. 

input #2 at www.plantengineering.com/information 

®

Ensure that your equipment is safeguarded at every 

point in the power distribution network with high-quality, 

cost-effective circuit protection and disconnection 

devices that meet UL standards. They’ll pay for themselves in no time! 

UL 98 Disconnect Switches 

starting at $83 

• Non-fusible and fusible rotary 

disconnect switches 

• Make/break loads up 

to 800 amps 

Motor feeder short 

circuit and ground 

fault protection 

Motor disconnecting 

means (NEC 

430.101-430.113) 

Motor branchcircuit 

short 

circuit protection 

(NEC 430.51- 

430.58) 

UL 489 

MCCBs 

starting at $179 

• Rated current up to 800A, max 600V 

• Standard and high-interrupting 

capacity types 

UL 248 

Current Limiting Fuses 

starting at $36 (10-pack) 

Class T, RK5, RK1 and Class J 

current limiting short circuit 

UL 489 

Miniature Circuit 

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protection up to 600A • 

• 

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• 1, 2, or 3-pole available 

• 10kAIC @ 277/480VAC 

Motor controller 

(NEC 430.81-430.91) 

Motor overload 

protection 

(NEC 430.21-430.44) 

Bryant Manual 

Motor Controllers 


UL 508 

Load Switches 


UL 98 and UL 508 

Compact Fusible 

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Switches 

starting at 

$18.00 

OSHA Lockout/ 

tagout disconnect 

(NEC 430.81-430.91) 

• Lockout / Tagout capability 

• 30, 40 and 60A up to 600 VAC 

• 2-pole and 3-pole switches 

• Quick make, slow break design 

• UL Listed as “Suitable as Motor 

Disconnect” under UL 508 

• 35mm DIN rail mountable or 

direct mountable 

• Loads from 16 to 125 amps 

• IP20 degree of protection 

• Up to 30A, utilizing Class CC 

or Midget fuses 

• 1, 2 and 3-pole models 

• Open fuse indication 

• Lockout/Tagout capability 

Control 

Transformer 

UL 1077 Supplementary Protectors 


UL 248 

General Fuses 

starting at $1.75 (5-pack) 

• Class CC, general 

purpose class M (Midget) 

and small dimension 

glass and ceramic fuses 

• Ideal supplementary 

protection up to 30 amps for 

branch circuits and end of line equipment 

PLC I/O 

Contactor 

Coils 

Relays 

• DIN rail mountable 

• Full line of auxiliary switches, alarm switches 

and padlock lockout accessories 

• B trip curve 6 to 60 amps 

• C trip curve 0.5 to 60 amps 

• D trip curve 0.5 to 40 amps 

www.automationdirect.com 

Go online or call to get complete information, 

request your free catalog, or place an order. 

1-800-633-0405 

input #1 at www.plantengineering.com/information

NEVER SETTLE FOR 

GOOD ENOUGH. 

Clean air is essential for keeping 

your employees and your equipment 

productive. Don’t risk downtime 

and damage to your most important 

assets with a sub-optimal dust 

collector or filters. Our broadest-in-theindustry 

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Donaldson Torit always delivers 

EXACTLY WHAT YOU NEED. 

Learn more about 

Donaldson Torit solutions 

DonaldsonTorit.com 

800.365.1331 


© 2012 Donaldson Company, Inc.

What’s INside 

November 2012 

Volume 66, No. 9 

6 Interactive 

9 In Focus 

23 In Practice 

93 Product Mart 

94 Internet Connection 

95 Advertiser Contacts 

96 In Conclusion 

76 Enhancing systems 

PLANT ENGINEERING (ISSN 0032-082X, Vol. 

66, No. 9, GST #123397457) is published 10x 

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2012 Product of the Year Finalists 

The next wave of innovation 

There are more than 100 finalists in 15 categories vying for your 

approval in this year’s Product of the Year voting. 

30 Automation & Controls 

36 Apps for Engineers 

37 Compressed Air 

38 Electric Motors & Drives 

40 Electrical Controls 

41 Energy Management 

42 Environmental Health 

43 Fluid Handling 

44 HVAC 

45 Lighting 

47 Maintenance Tools & Equipment 

49 Material Handling Systems 

51 Power Transmission 

53 Productivity Training Software 

54 Safety 

www.plantengineering.com PLANT ENGINEERING November 2012 • 3

Analyze power quality and 

calculate energy loss. 

Poor power quality. It affects how your 

facility operates. It affects your bottom 

line. Fortunately, there’s the new 

Fluke 435 Series II Power Quality 

and Energy Analyzer. It features 

the most advanced waveform and 

power efficiency functions available 

and calculates the cost of wasted 

energy. So don’t settle for half the 

job–do the whole job with Fluke. 

Learn more: fluke.com/pqandenergy. 


PlantEngineering.com 

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TO Audience 

THE EDITOR 

Management Director 

303-246-1250, REllis@CFEMedia.com 

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Automation Solutions 

71 Remote monitoring 

technologies lower costs, 

improve operations 

The latest remote communication technologies allow experts 

to monitor and control multiple plants from any location. 

76 Using sensors to enhance systems 

Recognize the limitations, then plan for redundancy. 

Maintenance Solutions 

81 Smaller, more flexible 

enclosures still 

need to be rugged 

Cabinets allow for safe and accesible 

storage, but can generate dangerous heat. 

Mechanical Solutions 

89 Particulates, liquids, 

oxidation contribute 

to oil contamination 

Oil discoloration should be addressed 

with high importance for optimal 

operation performance. 

9 In Focus 

Get Skills to Work formed to address skills gap, veterans training 

Georgia Tech study: Sales, Lean, skilled worker help needed 

Data center management more than cooling 

Hope is not an effective safety strategy 

Measuring quality through software 

Fine turning your preventative maintenance schedule 

PLANT ENGINEERING November 2012 • 5

INTERACTIVE 

www.PlantEngineering.com 

WHAT 2 CLICK 2 

Here are this month’s online highlights 

at www.plantengineering.com. Type the 

keyword into our exclusive search engine 

and find full details on each article: 

Keyword: SME student assessment: 

The Society of Manufacturing Engineers 

(SME) has been granted $292,000 from 

the U.S. Dept. of Energy to partner SME 

Student Chapters with existing Industrial 

Assessment Centers at universities nationwide. 

Keyword: Compressed dew points: 

Sampling is needed when direct measurement 

of the air is undesirable or is simply 

not feasible. This may be due to a high process 

temperature, the need to protect the 

sensor from water spikes, the added convenience 

of installing and removing the instrument 

from a pressurized process without 

shutting down the line, or wanting to make 

the measurement in a more convenient 

location. This paper shares tips on how to 

get a representative sample of the process 

gas and avoid potential sources of error 

caused by incorrect sampling practices. 

Keyword: Industrial wireless market: 

New research study from Frost & Sullivan 

projects massive growth for the wireless 

industrial automation market. While revenues 

are expected to more than double 

over the next four years, implementation of 

wireless technology still is lagging. Analysts 

attribute this to a lack of understanding 

about the full potential of wireless. 

Keyword: AME Hall of Fame: The 

Association of Manufacturing Excellence 

named four 2012 Hall of Fame inductees at 

its annual conference. The honor recognizes 

individuals who have distinguished themselves 

in the manufacturing community in a 

manner that is consistent with AME’s mission 

to inspire a commitment to enterprise 

excellence through shared learning and 

access to best practices. 

VIDEO 

Energy management trends 

in manufacturing 

CFE Media content manager 

Amara Rozgus sat down for an 

exclusive one-on-one interview 

with Jeff Drees, North American 

president for Schneider 

Electric, to discuss trends in 

manufacturing, including the 

increasing use of energy management 

and energy audits to 

identify and reduce the cost of 

energy to a plant. 

Scan the QR code above with your 

Smartphone or visit www.plantengineering.com/videos 

WHITE PAPER 

Effectively manage 

your fleet system 

A new white paper from Hyster talks about the most effective ways to manage 

your lift truck fleet systems. 

When lift truck fleets are not properly maintained or utilized efficiently, 

downtime increases, productivity is reduced and you may end up spending 

money when you should be making money. The challenge of properly 

maintaining your fleet can be resolved through an effective fleet 

management program. 

Fleet management programs help navigate hidden opportunities to reduce 

your materials handling spending. As you are confronted with difficult economic 

hurdles, the need to shed cost for sustainability is a must if you are to emerge 

from these economic times leaner, stronger and poised to take advantage of 

economic recovery. 

Visit www.plantengineering.com/media-library/white-papers to view the white paper. 

PRODUCT OF THE YEAR 

Cast your vote 

As a qualified subscriber to Plant Engineering, 

you are eligible to vote for the best products in 

this year’s Product of the Year program. Voting is 

open until Jan. 15, 2013, and the winners will be 

announced at the 2013 Awards in Manufacturing 

Event on March 18, as well as in the April 2013 

issue of Plant Engineering. 

Turn to page 29 or visit www.plantengineering.com/POY 

to read about this year’s finalists and cast your vote. 

2012 

6 • November 2012 PLANT ENGINEERING www.plantengineering.com

Machining 

without 

Coolant! 

Watch The 

Video! 

www.exair.com/79/49979.htm 

Replace messy mist systems & improve 

dry machining with clean, cold air! 

Extend CNC Tool Life 

The Model 5315 Cold 

Gun cools a two flute 3/8" 

carbide cutter on a CNC, 

increasing tool life by 50%. 

Ideal for diamond tooling. 

Milling & Drilling 

Fly cutters up to 460mm 

in diameter have been 

cooled with the Cold Gun. 

Dissipating heat with 

cold air extends tool life, 

increases speeds and feeds, 

and improves finishes. 

Chill Roll 

Cooling a roll with 20°F 

(-7°C) air keeps the material 

on the surface from 

bunching up, jamming 

or tearing. The metal 

surface transfers the cold 

temperature to the product. 

Tool Grinding 

Cold air eliminates heat 

cracking of carbide and tool 

edge burning during grinding 

and sharpening operations. 

Increased tool life between 

regrinds is the result. 

Increase tool life and machining rates! 

The Cold Gun increases tool life, tolerances and production 

rates by eliminating heat build up. It produces 20°F air 

from ordinary compressed air. The Cold Gun is ideal for dry 

machining or to replace messy mist systems. It eliminates 

the costly coolant purchase and disposal. 

• Low cost, portable, quiet 

• Won't freeze up during continuous use 

• No health problems from airborne coolant 

• Improves surface finish 

• No moving parts - maintenance free 

High Power Cold Gun 

Twice the cooling power of standard Cold Guns. 

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@EXAIR 


Fill one bulk bag per week or 20 per hour 

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Flexicon’s extra-broad model range, patented innovations and performance enhancements 

let you exact-match a filler to your specific cost and capacity requirements 

FILLER FOR PALLET 

JACK BAG REMOVAL 

Low profile version of patented 

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removal of filled bags using a 

pallet jack, eliminating the need 

for a forklift or roller conveyor. 

Low cost standard models offered 

with many performance options. 

BULK BAG FILLER USES 

PLANT SCALE 

Full length forklifting tubes 

allow positioning of this TWIN- 

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plant scale as needed, allowing 

you to fill by weight without 

investing in load cells and 

automated controls. 

FILLERS WITH AUTOMATED 

FEEDING SYSTEMS 

Every Flexicon filler is offered with 

pneumatic (shown) or mechanical 

(bottom right) feeding/weighing 

systems, as well as inlet adapters 

to interface with 

optional overhead 

storage vessels. 

COMBINATION 

BULK BAG/DRUM FILLER 

Patented SWING-DOWN ® filler 

features a fill head that lowers 

and pivots down for safe, easy bag 

spout connections at floor level, 

and a swing-arm-mounted chute 

for automated filling and 

indexing of drums. 

PATENTED 

SWING-DOWN ® FILLER 

Fill head lowers, pivots and stops 

in a vertically-oriented position, 

allowing operator to safely and 

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floor level and resume automated 

filling and spout-cinching 

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CANTILEVERED 

REAR-POST FILLER 

Offered with performance options 

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BASIC FILLER FOR 

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A lighter-duty version of the 

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chute dust vent as standard, and a 

limited list of performance options. 

PATENTED 

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Two heavy-gauge, on-center posts 

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Numerous performance options. First 

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.com 

See the full range of fast-payback equipment at flexicon.com: Flexible Screw Conveyors, Pneumatic Conveying Systems, Bulk Bag Unloaders, Bulk Bag Conditioners, 

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USA 

sales@flexicon.com 

1 888 FLEXICON 

CHILE 

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AUSTRALIA 

SOUTH AFRICA 

©2011 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world. 


+56 2 415 1286 

+44 (0)1227 374710 

+61 (0)7 3879 4180 

+27 (0)41 453 1871 

Z-1227

INFOCUS 

Get Skills to Work formed to address 

skills gap, veterans training 

Four major American manufacturers 

recently announced the creation of 

a coalition to fund and encourage military 

veterans to get the training needed to fill 

the manufacturing jobs shortage. 

The Get Skills to Work coalition 

will focus on accelerating skills training 

for U.S. veterans; helping veterans 

and employers translate military skills 

to advanced manufacturing jobs; and 

empowering employers with tools to 

recruit, onboard, and mentor veterans. 

It will be managed by the Manufacturing 

Institute and supported through financial 

and in-kind commitments from GE, Alcoa 

Inc., Boeing, and Lockheed Martin. 

“These initial investments will help 

15,000 veterans translate military experience 

to corresponding advanced manufacturing 

opportunities and gain the 

technical skills needed to qualify 

for careers in this growing 

sector,” the group said. 

“A strong manufacturing 

industry is 

central to the longterm 

health and success 

of our economy,” said Jeff 

Immelt, chairman and CEO of 

GE. “But as technology advances, 

skill sets must be upgraded to ensure 

companies have the talent to continue 

to fuel innovation. Today, many veterans 

are out of work, despite the nation’s 

growing industrial sector and increased 

demand for skilled workers. Through this 

initiative, we have an opportunity to help 

veterans with extraordinary leadership 

capabilities better compete for good paying 

jobs with a long-term future.” 

Reportedly 600,000 high-tech 

manufacturing jobs remain 

open in the U.S., and more 

than 82% of manufacturers 

report they 

cannot find people to 

fill their skilled production 

jobs. Meanwhile, one million 

veterans are expected to exit 

the armed forces over the next four 

years and will be transitioning to civilian 

careers. 

The coalition commissioned an online 

survey of more than 1,000 veterans and 

active duty military members preparing 

to transition to the private sector. The survey 

found that while 76% of respondents 

are confident they will be as successful 

in their careers as they were in the military, 

one-third do not feel equipped to 

Study: Returning vets say they have the skills to help manufacturing 

A 

new survey finds that veterans returning from military 

service believe their skills will translate well into the 

private sector, but don’t believe the private sector 

feels the same way. 

GE and the Institute for Veterans and Military Families at 

Syracuse University released the results of their “Voice of 

Veterans” survey to coincide with the announcement of the 

coalition between GE, Alcoa, Boeing, and Lockheed Martin. 

The four companies, working with the Manufacturing Institute, 

have developed the Get Skills to Work program to help 

train and deploy returning veterans for manufacturing jobs. 

The survey found that 76% of U.S. veterans and active 

duty military preparing to transition to civilian life are confident 

they can be successful in their private-sector careers. 

But 66% said they believe the skills they gained in military 

service are undervalued by private sector employers. 

More than 1,000 veterans and active duty personnel 

under the age of 45 took part in the survey. They said they 

want the same kind of training they received in the military, 

and believe their background and existing skills will translate 

well into private sector employment. 

“What stands out in this data is that veterans are motivated 

to make a difference beyond their military careers. 

Given their contributions, we must pay attention to the 

unique challenges and opportunities they face as they navigate 

the transition to civilian life,” said Mike Haynie, founder 

and executive director, IVMF. “There is a lot we can do to 

match the desire to work in dynamic, rewarding industries 

with training that creates a pathway for success.” 

“The U.S. manufacturing industry is growing, and we 

stand ready to provide our military veterans with the training, 

education, and mentorship they are seeking to build 

long-term, well-paying careers that make a positive difference 

in the world,” said Frank Taylor, chief security officer 

of GE. “The skills earned in the U.S. armed forces translate 

to today’s sophisticated, highly technical manufacturing 

industry, and we are confident that working together with 

America’s heroes, we are poised to drive American competitiveness.” 

The Get Skills to Work coalition’s goal is to bolster the talent 

pipeline, enhance American competitiveness, and give 

our nation’s veterans the skills and tools they need to compete 

for the jobs of the future. Coalition partners include 

The Manufacturing Institute, GE, Boeing, Lockheed Martin, 

Alcoa Inc., LinkedIn, Futures Inc., Atlantic Council, the Gary 

Sinise Foundation and Techshop. 

For more information about the Get Skills to Work coalition, 

visit www.getskillstowork.org. 


INfOCUS 

Mark Huber (from left) of Alcoa Inc., Gabriele P.M. Tyler, Deputy Director of Transition 

Strategic Outreach for the U.S. Army, and actor and veterans activist Gary Sinese 

discuss the formation of the Get Skills to Work coalition. Courtesy: GE 

overcome the challenges of the transition 

to civilian life; the percentage rises to 

nearly 48% when surveying active duty 

military who are scheduled to transition 

in two years or less. 

“Veterans offer the technical, leadership, 

and critical thinking skills that 

advanced manufacturing demands,” 

said Paula Davis, president of the Alcoa 

Foundation. “Forming the Get Skills to 

Work coalition and coordinating with 

nonprofits to train, recruit, and develop 

veterans is an exciting model that has 

the potential to change lives and produce 

a significant competitive advantage for 

U.S. manufacturers.” 

“We believe the Get Skills to Work 

initiative could have a major impact 

on the hiring of veterans nationwide,” 

said Rick Stephens, Boeing’s senior 

vice president of human resources and 

administration, and a U.S. Marine Corps 

veteran. “Using many of the same tactics 

and tools, such as a website for 

transitioning veterans that includes a 

military-to-civilian skills translator, 

we have hired and trained nearly 3,000 

veterans in the past 21 months for jobs 

at Boeing. It’s a proven approach for 

matching the skills of those who have 

served our country to the hiring needs of 

American businesses. We’re honored to 

be part of Get Skills to Work, and look 

forward to integrating our efforts with 

the coalition.” 

“America’s veterans want and deserve 

the opportunity to contribute to our society 

and provide for their families,” said 

Bob Stevens, Lockheed Martin Chairman 

and CEO. 

The program will consist of three elements: 

n Accelerating skills training 

To help prepare veterans whose military 

service experience doesn’t immediately 

qualify them for available manufacturing 

jobs, coalition partners will work 

with local community and technical 

colleges to establish the Manufacturing 

Institute’s Right Skills Now program, 

which fast-tracks industry-recognized 

certifications and offers training in core 

manufacturing technical skill areas. Partners 

will engage their regional supply 

base to ensure the certifications being 

offered meet the immediate skill needs 

of local employers, and will work with 

the U.S. Depts. of Defense and Veterans 

Affairs, as well as local military transition 

offices and bases, to recruit veteran 

participants. 

n Translating military experience 

into civilian opportunities 

Many veterans and employers have difficulty 

recognizing and translating the 

skills gained through military training 

and experience into civilian workforce 

skill sets. The Manufacturing Institute, 

working with Futures Inc., has created 

a digital badge system to help translate 

Among the findings of the “Voice 

of Veterans” study conducted by 

GE and the Institute for Veterans 

and Military Families at Syracuse 

University: 

n 76% of young veterans are 

confident they can be successful 

in their careers, despite the many 

challenges faced when transitioning 

to civilian life, and this confidence 

level increases with age. 

n 66% feel their skills are undervalued. 

Unparalleled work ethic, 

leadership, teamwork, discipline, 

and dedication are translatable 

skills they have to offer the civilian 

workforce. 

n 70% believe the skills they 

earned in the military align with a 

job in the manufacturing industry. 

n 79% are motivated to find 

educational opportunities to help 

them find and advance their civilian 

career. 

n Work/school balance (48%) and 

financial burdens (35%) pose barriers 

to their pursuit of education. 

n 76% want a civilian career that 

makes a positive difference in the 

world. 

n 78% seek a career that fills 

them with a sense of pride. 

n 62% believe companies have a 

responsibility to provide veterans 

with opportunities to enter and succeed 

in the civilian job market. 

applicable Military Occupational Specialty 

(MOS) codes, the U.S. military’s 

system for identifying jobs, to civilian 

positions in advanced manufacturing. 

n Empowering employers 

GE and the Institute for Veterans and 

Military Families at Syracuse University 

(IVMF) will develop and deploy a toolkit 

for employers focused on creating meaningful, 

lasting career opportunities for 

veterans in the advanced manufacturing 

sector. The toolkit will be available 

to employers participating in the U.S. 

Chamber of Commerce’s Hiring Our 

Heroes initiative and the 100,000 Jobs 

Mission, as well as the broader business 

community. P E 

For more information visit www. 

getskillstowork.org. 

10 • November 2012 plant engineering www.plantengineering.com

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INfOCUS 

Georgia Tech study: 

Sales, Lean, skilled worker help needed 

The 2012 edition of the Georgia Manufacturing Survey, 

conducted by Georgia Tech University, points to four areas 

of concern for manufacturers in that state. Topping the list 

is a need for more help in sales and marketing, with 36% of 

manufacturers citing this as a significant need. 

Manufacturers also want more help with the Lean manufacturing 

operation, cited by 32% of manufacturers, and worker 

skills, with 24% needing more technical workers and 16% 

needing more workers with basic skills. Energy cost management 

is cited by 21% of manufacturers as an area of concern. 

That percentage has doubled since 1999. 

The study also noted a significant increase in re-shoring 

of jobs to the state. According to a press release issued by 

Georgia Tech, nearly 16% of the companies responding to the 

survey said work had been transferred to them from outside 

Georgia, compared to slightly more than 14% that lost work 

to out-of-state facilities. 

“We have finally seen a crossing of the lines so that more 

companies are benefiting from in-sourcing than are losing 

to outsourcing,” said Jan Youtie, director of policy 

research services in the Enterprise Innovation Institute at 

Manufacturing Problems/Needs 

Problems/needs 2012 2010 Change 

Marketing and sales 36.0% 39.1% -3.1% 

Manufacturing 

process/Lean 

31.6% 31.6% 0% 

Technical skills 23.5% 18.8% 4.7% 

Energy costs management 21.4% 18.9% 2.5% 

Basic skills 16.4% 13.9% 2.5% 

While Georgia manufacturers still cite marketing and sales 

their biggest area that they need help with, the need for more 

technical skills, energy management and basic worker skills 

all rose in 2012 from 2010, the last time the study was conducted. 

Source: Georgia Manufacturing Study, Georgia Tech 

Georgia Tech. “It’s not a huge difference at this point, but 

it is a positive and consistent trend for the manufacturing 

community.” 

Plant Engineering spoke with Youtie about the implications 

for manufacturers in Georgia and elsewhere. 

PE: What are Georgia manufacturers able to offer 

right now that seems to be attracting manufacturing 

investment Is this occurring in specific sectors or 

across the board 

Youtie: Science-based manufacturers (those in medical device, 

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PE: The study also focuses on the relationship between 

technology and employment. Has the skills gap emerged 

as a problem for Georgia manufacturers, and how are they 

addressing the issue 

Youtie: This survey highlighted a reemergence of manufacturers’ 

concerns about technical skills, but we continue to see that 

investment in training is relatively low ($100 per respondent 

on average). 

PE: What are the barriers to sustainability Is it more 

profitable today to run a sustainable plant 

Youtie: Although we do not ask about the barriers to sustainable 

manufacturing, we do see that the vast majority of 

manufacturers are engaged in some aspects of sustainable 

manufacturing, such as eliminating waste materials sent 

to landfills, and more than half have a goal to eliminate air 

or water pollution. Both of those areas appear to have their 

2010 plans implemented by 2012. Other areas such as using 

renewable energy to run the plant still are not very common 

at all (set by only 7% of manufacturers in 2012), however, 

although the percentage with this goal has risen slightly 

from 2010 to 2012. P E 

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INFOCUS 

INDUSTRIAL EFFICIENCY: DEBUNKING THE MYTHS 

Data center management more than cooling 

By Kevin Brown, Schneider Electric 

Myth: Building my own data center 

is expensive, inefficient, and timeconsuming—but 

worth it to meet my 

specific IT needs. 

Due to advances in data center technology, 

modular and containerized data centers 

are now often a better alternative to 

customized data centers. For data center 

managers looking to increase their ROI, 

modular or containerized data 

centers are not only faster to 

deploy, but they’re also significantly 

more affordable and can 

offer better operational, efficiency, 

and processing benefits. 

The most obvious benefit to 

modular data centers is a drastic reduction 

in installation time. Traditional data 

centers take months or even years for 

construction, compared to just 10 to 16 

weeks for a modular data center. This is in 

part because they’re already verified for 

compliance in safety, energy efficiency, 

compatibility, and security. 

Cost savings is another major benefit. 

Not only will the upfront cost of installation 

be drastically lower than that for 

a traditional data center, but maintenance 

and operating expenses are also 

reduced over time. A modular approach 

can deliver capital expenditure cost savings 

anywhere from 10% to 20%, and 

operating expenditure cost savings from 

20% to 35%. 

Because of their manufacturing process 

and predictability, modular facilities also 

have a lower risk of operational human 

error. Systems have factory-verified 

operation and are tuned for maximum 

energy efficiency. Product defects are 

limited and software is preprogrammed, 

allowing technicians to spend less time 

troubleshooting and more time devoted 

to other critical IT issues. 

Myth: Sustainability in my data center 

is unattainable within my budget 

constraints. 

Sustainability isn’t just for big budgets. 

Using the right equation of affordable, 

widely available services and 

5 

Fifth 

in a series 

technologies to manage a data center’s 

energy supply and demand, businesses of 

all sizes can meet and exceed green and 

sustainability goals—without breaking 

the bank. Below are a few examples. 

Energy procurement: To ensure 

the most reliable and affordable clean 

energy is being sourced, data centers 

now have the option to work with outside 

sustainability service providers. These 

providers can help data centers with the 

full-time job of energy planning, 

monitoring, and reporting. These 

partners can also help reduce 

complexities involving price 

volatility, and control costs. 

Energy use: Just as we’re 

reminded to consume energy 

intelligently in our homes, data centers 

also need to be mindful of how and when 

they’re consuming energy. Some methods 

to reduce energy usage include: 

Natural cooling: Instead of an 

expensive HVAC system, use a free 

resource to cool your racks: outside air. 

While this is clearly best for data centers 

located in colder climates, it’s an ideal 

way to slash cooling costs and reduce 

energy use. 

Air containment strategies: Data 

centers routinely mix hot and cold air, 

limiting how effectively a system operates, 

as well as its overall capacity. An 

air containment system can be implemented 

by placing air tiles in the cold 

aisle, installing supply vents in the cold 

aisle and return vents in the hot aisle, and 

physically dividing the hot and cold aisles 

with a curtain or hard enclosure. This can 

return up to 25% in savings. 

And as the connecting element in a 

smart data center equation, demand 

response helps data centers get the most 

value out of their utility budget. By taking 

advantage of their utility’s demand 

response programs, businesses have the 

ability to determine when to best consume 

electricity, in conjunction with low 

rates. Plus, companies can also sell back 

unused energy (gleaned from efficiency 

and smart sourcing) to their utility at peak 

times, generating entirely new streams 

of revenue. 

Myth: Updating cooling is the only 

way to lower data center energy costs. 

There are many other tactics to be 

considered for lowering data center 

energy costs. Though cooling is a tremendous 

energy consumer, there are 

equally important areas you should be 

paying attention to if you want to slash 

your energy bills as much as possible, 

including air containment, higher voltage 

power distribution, more efficient UPS, 

redundancy requirements, and power 

architecture. Also consider: 

Power equipment efficiency: Data 

centers often fail to account for the heat 

produced by critical devices within a 

data center, such as UPS, transformers, 

transfer switches, and wiring. By cooling 

the heat generated by these devices, data 

centers maintain optimal conditions but 

also consume far more energy. 

Data centers should consider switching 

to more energy-efficient equipment, such 

as high-efficiency UPS, which have up to 

70% less loss than legacy UPS at typical 

loads, servers, and CRAC/CRAH units, 

which can be programmed to reduce or 

cease demand fighting entirely. 

Centralized management system: 

Advancements in data center infrastructure 

management (DCIM) software now 

allow data center managers to easily 

integrate and prioritize all IT equipment 

and functions into one application. This 

centralized point of control allows data 

center managers to holistically monitor 

temperatures, operations, security, and 

power utilization. 

While cooling should not be overlooked, 

data centers would do well to 

look at energy usage holistically. By 

implementing a variety of tactics, data 

centers can slash energy bills in a way 

that works best for the organization. P E 

Kevin Brown is Vice President, Data 

Center Global Solution Offer for Schneider 

Electric’s IT Business. 

GO TO: www.PlantEngineering.com 

Keywords: “Dubunking the Myths” to find 

Parts 1 through 4 of this series. 


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INFOCUS 

Hope is not an effective safety strategy 

By J.B. Titus 

It basic nature that businesses 

don’t want incidents to occur. 

And, at the same time employees 

don’t want to be hurt. Businesses 

generally, some only 

when confronted, don’t wish 

for exposure to unneeded regulation, unscheduled 

machine downtime, employee 

injuries, costly liabilities or the cost burdens 

associated with these issues. Yet, 

these are some of the negative results a 

business can expect as consequences of 

avoiding the required risk assessments 

for their machinery operations. 

Some of the potential liabilities of 

exposure (avoidable consequences) 

might be: 

Timing: Too many businesses still 

avoid the issue of compliance to the risk 

assessment requirement which extends 

to existing, new or modified equipment. 

The sooner the better to meet compliance 

requirements and avoid 

citations. 

Misapplied devices: Quite 

often safety devices are provided 

but are miss-applied because 

a hazard level was not properly 

assessed. For example, a Cat 4 

hazard could require a control 

reliable solution involving a Cat 4 safety 

rated switch with redundant contacts. 

A miss-applied device in this example 

could include; a single standard interlock 

switch, safety rated devices below Cat 

4, or an application which is not control 

reliable. 

Foreseeable misuse: A properly conducted 

machine guarding risk assessment 

will typically uncover misuse situations 

like; equipment malfunction, unauthorized 

process material, operating tooling 

beyond its useful life, unexpected loss of 

power, and reach over, under, around, or 

through guarding. 

Misapplied procedure: Lockout/ 

Tagout (LOTO) is frequently misunderstood 

and/or not always followed as 

prescribed by OSHA. LOTO incidents 

are preventable via frequent training, 

documenting procedures, not permitting 

shortcuts, and by establishing employee 

penalties for non compliance. 

Unidentified modes: All modes of 

operation and their related tasks need 

to be identified in order to reveal their 

related hazards. Unidentified modes 

include; setup, cleanup and preventive 

maintenance. 

The advice of industry experts is to not 

become aware of the importance of risk 

assessments only after a serious incident 

and the resulting OSHA citation, or the 

legal engagement, or the sever financial 

expenses which fall directly to your bottom 

line. “Hope” is not an effective strategy 

– proactive engaged machine safety 

leadership is! P E 

Read J.B. Titus’ blog, Machine Safety, 

at www.plantengineering.com/blogs. 

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INFOCUS 

Measuring quality 

through software 

Matthew Littlefield 

LNS Research 

LNS Research has released its 

Enterprise Quality Management 

Software Selection Guide, which 

looks at 18 major vendors in the 

spaces and offers comparisons on 

performance and applicability to 

individual industries. Matthew Littlefield, 

president and principle analyst 

at LNS Research, discussed with 

CFE Media the value of measuring 

quality with software, and how the 

acceptance of such tools is growing 

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Plant Engineering: In evaluating the top vendors for 

Enterprise Quality Management Software, what criteria 

would you say is most critical for an effective system 

for end users 

Littlefield: There are a number of factors that determine 

how well suited a particular vendor is for a particular client. 

First and foremost I think comes industry experience, some 

vendors have experience in life sciences, others have experience 

in discrete manufacturing like automotive or aerospace 

and defense, still others have started to develop experience 

in consumer products or food and beverage. The drivers and 

needs are very different in all these industries and very few 

vendors have expertise across all these industries. 

Second, I would say existing IT infrastructure, some companies 

are heavily invested in ERP, others have a large PLM 

footprint, still others have disparate systems at the enterprise 

level, again different vendors have different strengths in this 

regard. Finally I would recommend looking at the technology 

itself. Originally EQMS vendors were very form based, over 

time many have updated their technology to be work-flow 

based that has a more solid data model and ability to interoperate 

with other systems through web-services. 

Finally, is the vendor continuing to invest in areas like BI, 

Mobility, and an enhanced user-experience. Some companies 

are and others are still behind the curve. 

PE: Why is software the best measuring tool for quality 

What industries might benefit the most from such a 

system Conversely, which industries are not a good fit 

for EQMS 

Littlefield: Software is an important tool for a number of 

reasons but I think one that stands out the most is our changing 

business environment. Companies are continuing to expand 

globally, products are continuing to increase in complexity, 

regulations continue to expand, and consumer demands 

continue to increase. 

Companies that don’t specifically invest in a platform to 

manage how quality impacts the entire value chain and how 


18 • November 2012 PLANT ENGINEERING

quality addresses all these market drivers will be at a distinct 

competitive disadvantage. 

From an industry perspective, industries that have high 

risk products, high risk processes, a deep impact on consumers, 

or a restrictive regulatory environment are all candidates 

for EQMS, including life sciences, consumer products, 

discrete manufacturing, and process manufacturing. 


PE: You mentioned the education process is critical in a 

successful deployment of EQMS. How far into the organization 

does this training need to go 

Littlefield: For a quality culture to take hold, it truly has 

to go to the operator level. Continuous improvement, nonconformance 

management, compliance, and more all have 

to be managed at the most granular level possible. We are 

now seeing some companies that have 10,000-plus users on 

EQMS systems. 

“ 

For a quality culture to take hold, it truly has 

to go to the operator level. Continuous improvement, 

non-conformance management, compliance, 

and more all have to be managed at the 

most granular level possible. ” 

PE: What are the leading causes of failure for EQMS, 

or any operating system for that matter 

Littlefield: Very rarely is the technology to blame itself, 

although that could be the case with some vendors that have 

not kept based with investments in their products. Most likely 

that failure comes from executive leadership not promoting 

and believing in a quality culture. If executives do not walk 

the walk it can be very challenging to have the right culture 

and technology adoption flow through the organizations 

PE: What’s the potential ROI for a successful implementation 

Littlefield: ROI is tough to measure in the EQMS world and 

many companies don’t. Although there are two ways we are 

starting to see companies measure ROI. First is around the 

Cost of Quality and second is around risk reduction. Both are 

viable ways for measuring business success and companies 

that invest in EQMS can often see major improvements in 

these metrics, often providing an ROI in less than 1 year. 

PE: Why might this be a good time for manufacturers 

looking to upgrade their quality management process 

Littlefield: We have seen companies be most successful with 

EQMS in two major ways. One if there is a major quality 

issue or compliance issue at your company, adopting software 

maybe a very prudent step for correction. 

Second, if your company is focused on a new (or improving 

an old) operational excellence initiative, EQMS can help 

in the success of these initiatives and building quality into 

operational excellence. P E 

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plant engineering November 2012 • 19 


CONSULTING – SPECIFYING 

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INfOCUS 

Fine tuning your preventive maintenance schedule 

By Paul Lachance, Smartware Group 

What comes first: corrective or preventive 

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reduced labor force often set in and best 

laid plans slip. 

Example: Company X has older, inefficient 

ventilation in one of its production 

facilities. The HVAC breaks down 

frequently, is expensive to run, and finally 

BEARING PROTECTION RING 

SGR 

FINALIST 

management agrees to replace it with a 

brand new, more energy efficient system. 

Since the conversion, air quality 

and temperature have never been better, 

and the cost savings is tangible. 

During installation, the manufacturer 

strongly advises Company X to follow 

a recommended maintenance plan. The 

maintenance supervisor asks her administrator 

to make sure the PM calendar 

is set up in the CMMS. The team is so 

happy to not be dealing with the older, 

often malfunctioning system they wonder, 

“Why bother doing anything; the 

system is brand new!” 

PMs are dutifully set up and the automated 

reminders/PM work orders churn 

out every month. The challenge begins 

when the technician assigned tries to 

balance PM work orders on a combination 

of assets, including a shiny, new 

ventilation system and other antiquated, 

poorly-running systems that should be 

replaced. 

The reality is that technicians will 

likely continue to “MacGyver” older 

systems to keep them running and the 

new system will be ignored since it is 

humming along nicely. There are just not 

enough hours in the day. Reality forces 

us to make compromises. 

Sometimes these choices have to be 

made. If all of a sudden the CMMS issues 

an actual corrective maintenance work 

order for this system, it indicates that the 

team has to get back to a more frequent 

schedule, but it may not need to be as 

frequent as the manufacturer’s recommendations. 

A good CMMS system can deliver the 

information users need to better fine-tune 

their PM schedules. If a less-rigorous 

PM schedule gets the maintenance team 

slapped with a corrective work order, it’s 

time to adjust. Sometimes it is the other 

way around. If the CMMS system tells 

the maintenance manager ‘all is well’ 

with an asset, that may be a signal to 

shift resources to other equipment in 

greater need. P E 

Paul Lachance is president and chief 

technology officer for Smartware Group, 

which produces Bigfoot CMMS. Contact 

Paul at paul.lachance@bigfootcmms. 

com. 

20 • November 2012 plant engineering 

12-375 Shaft Volt Test Kit IsleHalf (PE-NOV2012).indd 1 10/3/12 12:01 PM

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® ® 

Hi-temperature Conduit 

Wire & Cable Management • Cable Protection Systems • Power Connection & Control • Safety Technology 

©2012 Thomas & Betts Corporation. All Rights Reserved. 


Driven by Efficiency 

Setting New Milestones in Performance 

Hey, I'm Trey, Product Marketing Manager at Atlas Copco Compressors. It's my great 

pleasure to introduce the next generation of the GA oil-injected screw compressor range. 

The GA 40-125 horsepower range has been redesigned in line with Atlas Copco's 

commitment to continuous innovation. Featuring new and improved components that 

provide unparalleled performance, sustainability, efficiency and reliability, the VSD models 

deliver up to 35% energy savings, while the premium efficiency fixed speed models offer 

industry leading Free Air Delivery (FAD). 

Visit our dedicated website to learn how this new compressor range can boost your 

productivity www.atlascopco.com/drivenbyefficiency or call 866-688-9611 to learn more 

about us, our products, and how we have earned and will continue to earn our reputation. 


© Copyright 2012 Atlas Copco Compressors LLC. All rights reserved.

INPRACTICE 

Make your plant floor time 

productive 

I 

frequently pose this question to managers: “How much time 

do you spend on the floor” I get responses that run the 

gamut from “I don’t need to go to the floor” to “I’m on the 

floor all the time.” Of course, the amount of time that you 

spend on the floor is directly proportional to where you sit in 

your organization’s hierarchy. 

You’ve probably heard the phrase “Go to the gemba.” From 

what I can ascertain, this means go to where the work is being 

done. I absolutely, wholeheartedly, agree with this concept. 

However, the amount of time you spend there and what you 

get accomplished are not always proportional 

to each other. 

So, how do you make your time in 

the work area more productive First, 

let’s talk about the inverted pyramid. 

This is not a new concept, and it can 

be used in a myriad of ways. The pyramid 

that I am talking about stands 

on its point, and like the traditional 

pyramid, the head of the organization 

resides at the point. The difference 

here is that now the point supports the entire organization 

instead of the rest of the organization supporting the point. 

Ask yourself a question, no matter where you sit on the 

pyramid. How much time do you spend making sure that daily 

customer demand is met And how do you know that it is being 

met Can you walk into the workplace and understand where 

you stand in meeting daily customer demand In most places 

that I have worked, it is not easy to determine. That information 

is usually communicated at the morning production meeting. 

And where do these meetings usually take place If you said 

“the floor,” you are in a small minority. 

Meeting customer demand 

Whose job is it to meet daily customer demand The operators 

who are in the trenches every day making the equipment/ 

processes operate. About 90% to 95% of the time, they need 

to be focused on meeting daily customer demand. And what 

should they do with the other 5% to 10% Teach them to solve 

problems in order to create greater stability and increase efficiency. 

With the operators taking on the biggest burden in 

order to meet customer demand, what does everyone else do 

Everyone else supports the operator; thus the inverted pyramid. 

A typical structure could include operators, team leaders, 

group leaders, assistant managers, and managers, with each 

lower level of the pyramid supporting the level above it. Visual 

By Kimo Oberloh, Life Cycle Engineering 

As the operators understand what is 

causing the line to be unstable, they 

will take action to constantly reduce 

the variation. This could be problem 

solving and implementing the 

solutions themselves, thus the 5% to 

10% dedicated to improving the line. 

controls are what will allow you to see what is happening on 

the shop floor. It is how the operator communicates to the 

management team what is happening in their process. Things 

like progress control boards, color coding, and having specific 

locations for tools, work in process, raw materials, and 

finished goods will help you to identify the current condition 

of satisfying customer demand for that particular day. Even 

if you are producing an item that gets completed only once 

every 45 days, it can still be broken down into weekly, daily, 

and even hourly targets. 

One of the foundational visuals is 

the progress control board. It can display 

everything about an area that is 

required to understand what is being 

done to satisfy customer demand. It 

will always contain a temperature 

of where the area stands in meeting 

customer demand. Some will call 

it an hour-by-hour chart; I call it a 

feeling. When you look at it, you get 

a feeling for whether the process is 

performing well or not. 

Another integral part of the progress control board is the 

Pareto of reasons for missing target (or capacity). As the operators 

understand what is causing the line to be unstable, they will 

take action to constantly reduce the variation. This could be 

problem solving and implementing the solutions themselves, 

thus the 5% to 10% dedicated to improving the line, or it could 

be listing items on an action item log for someone else to handle. 

This brings us to the final mandatory item on the progress 

control board—the action log. When the operators run into 

an item that they themselves cannot solve, they will put it on 

the action log. It is then the responsibility of the people that 

are lower on the pyramid to review these action items and act 

on them. 

Allocating time 

How much time should you spend on the floor If you can 

adhere to the 90%-95% rule for the operators, the team leads (or 

supervisors, or assistant general foreman) will spend 70%-80% 

on daily demand and 20%-30% looking ahead. They will look 

one week to a month out and see what is coming up. What do 

they have to do with manpower Are temps required Are there 

any tests that will need to be run that require special attention 

What is required of the team lead to support the operator in 

making the line more stable and efficient 


INPrACTICE 

The next level down (group leader, assistant manager, foreman) 

should spend 50%-60% of their time satisfying customer 

demand and the remainder of the time looking ahead at what is 

happening this month or this quarter. Each level needs to ask 

what it can do to support the operator. 

As we progress another level down, managers should allocate 

25% of their time to meeting daily demand, and 75% to planning 

for the year. Are you starting a 

new line What needs to be done in 

the holiday shutdown How are we 

going to staff for the summer peak, 

what do I need to do to satisfy the 

targets and objectives for the year 

and, of course, what can I do to 

support the operator At the bottom 

of the pyramid (CEO, COO, plant 

director), leaders focus 5% to 10% 

on daily demand and 90% to 95% on looking ahead. 

When we look at these percentages more closely, if the bottom 

of the organization were to spend 10% of their day making 

sure that customer demand is met, that would be one hour per 

day (assuming that most management teams usually work a 

10-hour day). This would entail walking the floor, observing 

the progress control boards, and seeing what items on the action 

list require their attention. This would also include walking the 

floor with the team members that report to you. 

How much time do you spend making 

sure that daily customer demand is met 

And how do you know that it is being 

met Can you walk into the workplace 

and understand where you stand in 

meeting daily customer demand 

The content on the rest of the progress control board is up 

to you. Remember, you have the daily progress sheet, Pareto 

of reasons for not meeting plan (or capacity), and the action 

list of what is being done to solve the issues. Be careful that 

the action log does not become a whine sheet. There should 

only be about two to three actions on the list. This is because 

in large plants with a lot of progress control boards you need 

the ability to make sure that the 

actions identified are being solved. 

Other items that you could 

place on the board are items that 

will roll up to the overall metrics 

of the company. These usually fall 

into the categories of quality, cost, 

safety, and, of course, delivery. All 

metrics should roll up and down to 

support policy deployment. 

So while the question, “How much time do you spend 

on the floor” is very relevant, because no one is excused 

from spending time on the floor, maybe the real question 

should be, “How productive is the time that you 

spend on the floor” P E 

Kimo Oberloh is a Lean manufacturing subject matter expert 

at Life Cycle Engineering (www.lce.com). Kimo can be contacted 

at koberloh@lce.com. 

Surface Finishing 

Consumables 

Shot Blasting 

Send us your challenge...Rosler can find a better way. 

It may be as simple as upgrading your media…or maybe a different process would achieve the surface 

finish you need. From aerospace and automotive, to medical and general manufacturing, our state-ofthe-art 

test lab is here to solve your mass finishing and shot blasting challenges. Rosler specializes in 

providing complete, automated solutions and consistent, repeatable results for superior parts finishing. 

Visit us at www.rosler.us or call us at 269-441-3000. 


TWO GREAT 

COMPANIES. 

ONE BRIGHT 

FUTURE. 

How do you create a global company built 

for the future By combining two powerful 

histories in pursuit of a bold vision—to help 

companies around the world contribute to 

healthier, safer environments. 

Building on the achievements of Pentair and Tyco’s Flow Control 

businesses, comprised of Valves & Controls, Thermal Controls 

and Water & Environmental Systems, the new Pentair delivers 

exceptional depth and expertise in filtration and processing, flow 

management, equipment protection and thermal management. 

From water to power 

From energy to construction 

From food service to residential 

We’re 30,000 employees strong, combining inventive thinking 

with disciplined execution to deploy solutions that help better 

manage and utilize precious resources and ensure operational 

success for our customers worldwide. Pentair stands ready 

to solve a full range of residential, commercial, municipal and 

industrial needs. 

PENTAIR.COM 


Energy Consumption: 

How it Relates to Performance in 

Refrigerated Compressed Air Dryers 

Timothy J. Fox | Research and Development, SPX 

Those in charge of specifying and 

purchasing equipment for industrial compressed 

air systems have many decisions to 

make. The design of a proper compressed 

air system does not end after determining 

the quantity of air required (i.e., the air 

compressor and receiver tank); the user 

must also pay particular attention to the 

quality of the air that his or her process 

needs. Today’s optimal air systems demand 

less moisture, less particulates, less oil aerosols, 

and less oil vapor than ever before. 

For most users, a refrigerated-type 

compressed air dryer will satisfy their 

requirements for moisture removal. 

With so many manufacturers offering 

“equivalent products”, each with promises 

of delivered pressure dew point, pressure 

drop and consumed electrical power, how 

does one make an intelligent selection 

This paper will address power 

consumption, and how it relates to a 

refrigerated dryer’s ability to remove 

moisture. It will explain how a potential 

buyer can determine if the stated 

performance is possible with the power 

consumption that is published in the 

manufacturer’s literature. 

an SPX Brand 

For more information please contact: 

Hankison.inquiry@dehydration.spx.com 

or visit our website at 

www.hankisonintl.com 

ple201211_SPX_whitePprHLF.indd 1 


10/29/2012 3:22:28 PM 

Four Things You Need to Know About 

Compressed Air Dew Point Sampling 

Sampling is needed when 

direct measurement of the air 

is undesirable or is simply 

not feasible. 

This may be due to a high process 

temperature, the need to protect 

the sensor from water spikes, the 

added convenience of installing 

and removing the instrument from 

a pressurized process without 

shutting down the line, or wanting 

to make the measurement in a 

more convenient location. 

To get a representative sample of the 

process gas and avoid potential sources 

of errorcaused by incorrect sampling 

practices, the following aspects should 

be considered. 

• Changing the pressure of the gas 

changes the dew point 

• To avoid condensation the dew point 

must be below the ambient temperature 

in the sampling line 

• A leak-tight sampling system 

construction is essential 

• Sampling in still air should be avoided, 

however low air flow is okay 

Download the White Paper at 

knowledge.vaisala.com/SampleCell 

www.vaisala.com/compressedair 

sales@vaisala.com 

ple201211_whtPprHLF_vaisala.indd 1 


10/12/2012 10:17:06 AM

Maximize Uptime and Profits Through 

Effective Fleet Management Practices 

Pat DeSutter | Director NMHG Fleet Management 

This paper from Hyster Company discusses lift truck 

fleet management. From planning and use strategy 

to understanding total cost of ownership, this white 

paper helps any operation with a fleet of lift truck 

equipment to understand how to effectively and 

efficiently manage that fleet. Topics included in this 

paper are challenges to fleet management, key 

elements of fleet management, total cost of 

ownership, replacement planning, telemetry and 

outsourcing. 

One central challenge presented to lift truck fleets is 

hidden cost. Multiple service providers can add an 

unexpected financial and administrative burden to the 

fleet’s operation. With only an estimated 20 percent of 

an operation’s materials handling costs going to the 

initial purchase of the lift truck, the remaining 80 

percent is composed of maintenance, operator and 

fuel costs. A proper understanding of total fleet management 

from purchase to operation helps a company 

to review all associated costs and asset utilization. 

Several key element of true fleet management are also 

outlined, including proper planning, which is essential 

as lift trucks have an economic life of approximately 

10,000 to 12,000 hours as a general rule. 

While that life varies 

depending on maintenance 

practices 

and operational 

conditions, it is a 

reminder to plan not 

only the usage of 

the trucks, but also their replacement, to avoid costly 

downtime or increased maintenance expenses. 

Hyster’s FleetSmart web-based reporting system 

allows managers to monitor and measure the 

fleet’s utilization, specific truck cost per hour and 

overall operating expenses. After reviewing many 

of the factors necessary to effectively manage and 

maintain their fleet, some operations choose to 

sign agreements with lift truck manufacturers or 

dealers to provide expertise and management assistance. 

Capitalizing on years of experience, a strong 

dealer network and utilization of latest technology, 

Hyster Fleet Services can deliver unmatched results in 

reducing costs and maximizing productivity. 

Download the paper at: 

http://www.hyster.com/AMERICAS/EN-US/FLEET 

SERVICES/FleetManagementWhitePaper.htmx 

1-888-FLT-SVCS 

www.hyster.com/Americas/en-US/FleetServices 



2012 Finalists 

If innovation is one of the best indications of 

a strong manufacturing economy, the finalists 

for the Plant Engineering 2012 Product 

of the Year awards are pointing the way to a 

bright future. 

Entries in this year’s contest were up by 

more than 35%. This year’s crop of 

finalists covers 15 categories, including 

our newest category—Apps for 

Engineers. This points toward a greater 

use of handheld and Smartphone 

devices on the plant floor, and we 

expect this to be a very large category 

in future years as more widespread 

adoption of apps and mobile devices 

continues. 

Just as exciting this year are the 

two categories with the most entries. 

Automation & Controls is a category 

that highlights the desire of manu- 

facturers to measure and manage their 

manufacturing process in the most efficient 

fashion possible. The Safety category 

highlights that the most important 

asset on the plant floor is still 

the human one. 

This year’s 116 finalists stretch 

across all areas where a plant 

manager’s influence is felt and 

his knowledge is required. From 

motors and drives to maintenance and lighting, 

the things a plant manager must specify 

and purchase perform very different functions. 

They all have one common element: they 

must help him or her do the job better, smarter, 

safely and more efficiently. That has been 

the hallmark of 

Plant Engineering’s 

Product of the Year program for the 

past 25 years. 

It might have been tempting to make 

a bigger deal out of the 25th anniversary 

of Product of the Year. People 

tend to like anniversaries and birthdays, 

especially a silver anniversary 

year. But Product of the Year is important 

each year, on its own merits. We 

certainly hope the cumulative effect of 

Product of the Year has helped improve 

your operation each year. But each 

year, our task is simple: We showcase 

the best in innovation each year, and 

then put it in the hands of our readers 

to determine the best of that best. 

In 2012, for the 25th time, we again 

give the decision of this year’s Product 

of the Year winners to you. We 

hope you vote, and we hope you make 

use of this year’s outstanding innovations 

in manufacturing products. 

–Bob Vavra, Content Manager 

By Brittany Merchut, Content Specialist 

www.plantengineering.com PLANT ENGINEERING November 2012 • • 29 29


Product of the Year 

Automation & Controls 

Wireless sensor 

network 

Wireless network access point 

The 802.11 WiFi Access Point for Industrial M2M Applications 

provides users with wireless networking capabilities. 

The access point appears as an embeddable module, 

which allows original equipment manufacturers to Wi-Fienable 

their products. The access point also appears as 

an external Ethernet access point, which provides the 

same functions as a stand-alone box. The access point 

technology allows the access point device to become its 

own Wi-Fi network communicating with other devices. The 

802.11 WiFi Access Point contains an Ethernet port with 

two serial ports, providing more port configuration and 

connectivity tools. 

B&B Electronics Mfg. 

www.bb-elec.com 

The SureCross Q45 

is a wireless photoelectric 

sensor solution 

developed for 

industrial automation 

applications. The Sure- 

Cross Q45 improves 

efficiency in control 

and monitoring applications 

through the 

integration of a scalable, 

wireless sensor 

network infrastructure. 

The SureCross Q45 can be used for applications such as 

cable replacement, moving applications, remote applications, 

and productivity solutions. 

Banner Engineering Corp. 

www.bannerengineering.com 

Fan control 

BAFWorks is a fan application that allows users to control 

an unlimited number of Big Ass Fans products from a 

particular location. This application eliminates individual 

controls in large facilities by providing access to real-time 

fan speed and status of all fans. The BAFWorks application 

is available for all industrial overhead Big Ass Fans 

products. The application was designed specifically for 

the new industrial line of fans but is also compatible with 

previous generations. 

Big Ass Fan Co. 

www.bigassfans.com 

Communication cards 

The C441 Ethernet series of 

communication cards allows 

customers to select Ethernet/IP, 

HTTP web services, Modbus RTU 

communication protocols, and Modbus in a single card. The 

series contains added communications including options 

to configure, control, and monitor systems. Users have 

the ability to use one network for control and another for 

monitoring. The available Web services provide a Webbased 

graphical user interface. The series is compatible 

with Eaton C440, XTOE, and C441 electron motor protection 

relays, and S611 soft starters. 

Eaton Corporation 

www.eaton.com 


Panel wiring system solution 

The SmartWire-DT System replaces 

multiple wires used to connect motor 

control components with a single cable. 

The system allows users to easily integrate 

with the original equipment manufacturer’s 

preferred industrial network. 

The SmartWire-DT system uses an 

eight-conductor, flat cable located in the 

control cabinet to connect motor starters, 

pushbutton actuators, and indicator lights. 


www.eaton.com 

I/O expansion series 

The I/O Expansion Module is a new set of products to 

help customers achieve optimal performance, faster ROI, 

and customization for communication networks. The I/O 

Expansion Module offers an increased degree of monitoring, 

control and optimization, and flexible wired and 

wireless I/O. The I/O Expansion Module provides faster 

access time for up to 192 I/O points. The new module’s 

products carry the same measurement accuracy of analog 

inputs and can snap directly onto FreeWave radios or 

connect to other serial communication devices. With the 

I/O Expansion’s flexibility, the module can be used for a 

range of applications. 

FreeWave Technologies 

www.freewave.com 

Operator interface and controller 

The XV Series HMI-PLC incorporates programmable 

logic controller functionality and integrates with the Eaton 

SmartWire-DT system. The XV Series HMI-PLC combines 

control, visualization, and data management tasks in one 

device. The design of the XV Series removes the physical 

PLC, incorporates logic into the operator interface, and 

provides a single software package. The series has an 

optional integrated SmartWire-DT master, eliminating the 

need for a gateway. The SmartWire-DT device connects 

directly into the back of the panels. 


www.eaton.com 

www.plantengineering.com plant engineering November 2012 • 31




Lighting control 

panels 

The 16- and 24-relay 

CX Commercial Lighting 

Control Panels can 

be ordered as Master 

and Secondary Panels 

enabling two panels to 

be connected together 

on one project. There is 

an LCD user interface 

located in the door with 

scrolling menus to program, 

check status, or 

update the pane. The 

CX Commercial Lighting Control Panels are available in 

relay sizes of 4, 8, 16, and 24 with four types of relays. 

The programming capabilities of the panel include 365- 

day programming with astronomical and real-time clock. 

Hubbell Building Automation Inc. 

www.hubbell-automation.com 

Wall switch 

sensors 

The LightHAWK Wall 

Switch Occupancy Sensor 

line has expanded 

to include a suite of wall 

switch occupancy sensors 

with neutral connections. 

The line has sensors available 

in passive infrared, 

ultrasonic, and dual-tech 

models with single or dual 

relays, several override 

options, and a complete 

palette of architectural 

finishes. All of the sensors 

come with a built-in photocell with SuperSaver mode. 

Hubbell Building Automation Inc. 

www.hubbell-automation.com 

Recorder/ 

controller 

Eurotherm 

Nanodac recorder/ 

controller’s latest 

edition includes 

greater storage 

flexibility for longer 

local data 

archiving, store 

and forward data 

retrieval, and connectivity 

to Invensys’ 

Wonderware Historian. The nanodac record/controller 

is best used as a local historian to third-party equipment, 

but it can be used as a stand-alone device. The nanodac 

recorder/controller has 50 MB of flash memory for data 

storage, an on-screen help system, and remote viewing 

functionality. The device also offers the option to provide 

two high-stability PID looks with the unique Eurotherm 

Autotune facility. 

Invensys Operations Management 

iom.invensys.com 

Control and simulation 

software 

The I/A Series is a control 

system with an Intelligent 

Marshalling solution and highperformance 

Foxboro Control 

Software and Simulation Software. 

The I/A Series features a 

Universal Fieldbus Module that 

eliminates the need for marshalling. 

Designed to improve 

user experience, the software 

embeds Invensys’ ArchestrA 

System Platform and Wonderware InTouch HMI in the 

system. This allows for integration of plant devices, systems, 

databases, and software applications. The software 

has the ability to simulate, including dynamic control of 

time, alarms, and trends using the same configuration 

files used in a live I/A Series DCS. 


iom.invensys.com 


Compact gearhead 

The Nexen Harmonic Gearhead has a short 

and rigid design combined with a large, rugged, 

crossed-roller output bearing that can 

handle all combinations of radial, axial, and 

overturning moment loads in a compact envelope. 

The Harmonic Gearhead is available 

with Nexen’s Roller Pinion System through 

the integration of the gearhead into the pinion 

without any added length. This allows for the 

maintenance of zero backlash from the driving 

motor shaft through to the driven load. The 

RPS has a unique roller pinion/rack combination 

that can be adapted to any application. 

Nexen Group Inc. 

www.nexengroup.com 

Modular HMI 

The GP-4000M Series Modular HMI allows users to 

easily monitor conditions and the operating environment in 

real time. The series offers a full graphics touchscreen with 

a selection of serial or Ethernet connections. The series 

design is energy saving with its on-board LED backlight, 

and a dimmer setting used to stand-by the display after 

being idle. The GP-Viewer EX software provides remote 

monitoring functions such as checking the screen from a 

remote office. 

Pro-face 

www.pro-face.com 

Automation communications platform 

The KEPServerEX 5.9 industrial automation communications 

platform has new electronic flow measurement 

capabilities and Wellsite Information Transfer Specification 

Level 0 drivers. The new solutions ensure that systems 

and devices supporting pipelines, wells, and drilling rigs 

can gather and share vital operational information. The 

new drivers with EFM capabilities have the potential to tap 

into stored data to manage, collect, monitor, and distribute 

information. The WITS Level 0 drivers provide quick and 

easy access to real-time drilling and mud logging data to 

offshore drilling platforms, onshore rigs, well sites, and 

other geographic sites. 

Kepware Technologies Inc. 

www.kepware.com 





Wireless 

monitoring 

system 

VIBCONNECT 

RF is a wireless 

condition monitoring 

system for 

machine components. 

The system 

monitors the 

condition of roller 

bearings and other 

rotating components, 

and detects damage caused by cavitation. The 

VIBVONNECT bridge acts as the central receiver as it 

processes the data from the sensor units, transmitting 

it through the operator’s network. Operators can assess 

machine vibration, bearing condition, and temperature 

through the variety of analytical functions available. 

Prüftechnik Group 

www.prueftechnik.com 

Programmable automation controllers 

The Allen-Bradley CompactLogix 5370 programmable 

automation controllers include 5370 L1, L2, and L3 controllers. 

These controllers have enhanced performance and 

motion capabilities while leveraging the common design 

and networking environment of Rockwell Automation’s 

Integrated Architecture system. The CompactLogix 5370 

offers performance and cost competitiveness for machine 

builders requiring up to 16 axes of complex motion on 

EtherNet/IP. The series offers the same processing speed 

upgrades as the ControlLogix 5570 series, but with more 

than twice the processing speeds. 

Rockwell Automation Inc. 

www.rockwellautomation.com 

Virtual image 

templates 

Power monitoring software 

StruxureWare Power Monitoring 7.0 Software is a software 

application that tracks real-time power conditions 

to improve efficiency, availability, and reliability. The software 

has a Web-based interface allowing users to monitor, 

analyze, and report on energy usage and power quality 

information. The software includes several new libraries 

for common real-time values, alarm views, and reports. 

StruxureWare Power Monitoring can function as a standalone 

software application and can connect easily to other 

StruxureWare software within suites, developed to address 

the unique needs of key market segements. suites. 

Schneider Electric 

www.schneider-electric.com 

The PlantPAx Virtual 

Image Templates 

deliver the core system 

elements as preconfigured, 

drop-in 

templates on a USB 

hard drive. Delivered 

in an open, virtualformat 

file, and supported 

and tested 

for use with VMWare 

vSphere, the Engineering 

Workstation, 

Operator Workstation, and Process Automation System 

Server templates are provided. The pre-installed and preconfigured 

Virtual Image Templates help reduce validation 

costs and initial engineering time, simplify upgrades, and 

patch management and enhance scalability. 




Comfort panels 

The SIMATIC HMI Comfort Panels feature the 

same functionality and performance across the 

entire product range. The panels come in different 

size of displays, including high-resolution, 

brilliant, and widescreen, and can be adapted 

for any application. The SIMATIC HMI Comfort 

Panels can switch off the displays of the units in 

break times. The panels are configured using 

TIA Portal based SIMATIC Step 7 and SIMATIC 

WinCC engineering software. 

Siemens 

www.siemens.com 

Compact CPU 

The SIMATIC S7-1215C is equipped with 100 

kb of user memory, a second PROFINET interface, 

two analog outputs, and fast outputs for 

controlling as many as four stepper motors. The 

controller offers 14 digital inputs, 10 digital outputs, 

two analog inputs, and two analog outputs. 

The SIMATIC S7-1215C can replace relays and 

contactors, convey systems, and pump control 

and energy management through to distributed 

tasks in a complex automation network. 

Siemens 


Sales resource 

planning software 

Atlatl-Sales Resource Planning 

Software is designed to support 

manufacturing and industrial sales 

and streamlines the engineer-toorder 

sales process. The software 

merges all elements of manufacturing 

sales processes including 

client data input, product demonstration, 

and configuration, as 

well as specification gathering 

engineering, and drafting. 

SixAxis LLC 

www.sixaxisllc.com 

Now the vote 

is yours… 


Plant Engineering subscribers 

with a valid e-mail address will 

receive the 2012 Product of the 

Year ballot. Simply fill it out, click ‘Submit,’ and let 

your vote for this year’s best products be counted. Then, 

in the April 2013 issue of Plant Engineering, meet the 

2012 Product of the Year award winners honored at our 

2013 Awards in Manufacturing Event in Chicago. 




Apps for Engineers 

Software platform application 

aPriori 2011r2 is a software platform that offers functionality 

and enhancements that expand a platform’s 

cost-optimization capabilities for companies with hightolerance 

machining requirements. The software platform 

has upgraded its abilities to create detailed tooling cost 

estimates for components. A flexible and powerful costing 

engine allows for instant and precise determination of the 

cost of a part or product from a CAD model. aPriori 2011r2 

has the capability to reassess and provide updated product 

costs as design changes are made or new product specs 

are introduced. With the software platform, companies 

are able to make better design and production decisions 

while reducing costs. 

aPriori Inc. 

www.apriori.com 

Product and technical 

information application 

The POWEREDGE mobile application provides real-time 

access to Eaton’s electrical catalogs, videos, and training. 

Electrical products can now be searched, selected, and 

located from an Apple device. The application is created to 

engage, educate, and enable users to find the product and 

technical information. Through the POWEREDGE mobile 

application, users can learn more about Eaton’s products 

with direct access to the electrical product catalog. The 

design of the application helps users find information on 

solutions to improve reliability, efficiency, and safety of 

systems they manage. 


www.eaton.com 

HMI software application 

The Wonderware InTouch 2012 software is the primary 

application of the company’s InFusion Enterprise Control 

System. The software offers users the ability to quickly and 

easily create standardized, reusable HMI and real-time 

decision support applications. The application’s graphics, 

ease of use, efficiency, and support allow users to help 

drive business optimization. 


www.invensys.com 

Data processing application 

The iQagent is an application that enables users to display 

live process data, documents, and resources about a 

given point of interest (POI) while connected to the plant 

wireless network. POIs are configured on the plant floor 

and then are tagged using a QR Code. POIs contain a Data 

View showing live process values and Info View containing 

links to documents and resources. On the plant floor, users 

can scan the QR Code and view data or other resources. 

iQuest 

www.iquest.net 


Compressed Air 

Air nozzle 

EXAIR’s Stainless Steel Super Air Nozzle offers 6.6 lbs of 

blowing force for blow-off, cooling, and drying applications 

in corrosive, high-temperature, food and pharmaceutical 

environments. The air nozzle has an aerodynamic design 

that directs compressed air to a single point of convergence, 

allowing a concentrated stream of high-velocity 

airflow. The nozzle contains applications including ejection 

of heavy parts, drying, part and machinery cleaning, chip 

removal, liquid blow-off, and cooling hot parts. 

EXAIR Corporation 

www.exair.com 

HOC dryers 

Ingersoll Rand’s 

new line of heat-ofcompression 

(HOC) 

dryers provides flexibility, 

reliability, and 

energy efficiency in 

a low-profile package. 

The dryers use 

heat produced during 

the compression process, 

which allows for 

instrument-quality air 

to be delivered using 

virtually no energy. 

The dryers contain 

Smart Control technology, which adjusts dryer operation 

to minimize dew point and temperature spikes. To prevent 

wasting compressing air, the dryers feature no-loss drains. 

The HOC dryers by Ingersoll Rand can be used with multiple 

compressors, reducing footprint requirements. 

Ingersoll-Rand plc 

www.ingersollrand.com 

Rotary screw 

air compressors 

Ingersoll Rand’s 

R-Series range of 

rotary screw air compressors 

is available 

in fixed speed and Nirvana 

variable speed 

drive. The new range 

of compressors comes with the Xe-Series controller, featuring 

a high-resolution LCD color display. The controller 

provides access and remote control of the compressor from 

any tablet, smartphone, or PC. The compressors have an 

integrated Total Air System dryer and filtration option that 

provides clean, dry air in a single package. The new design 

of the compressors reduces maintenance and allows for 

easy service with the swing-out separator covers, longer 

life consumables, and easy-access hinged doors. 

Ingersoll-Rand plc 

www.ingersollrand.com 

Portable air compressor 

Sullair Corporation’s E900H Portable Air Compressor is 

designed to combine the clean, quiet efficiency of electric 

drive technology with the Sullair legacy of rugged air ends 

and portable compressor designs. The compressor delivers 

900 cfm at operating pressures up to 150 psig. The E900H 

portable compressor features the Sullair AF System that 

allows the compressor to process equipment and other 

industrial applications. The compressor comes equipped 

with a built-in high-capacity after-cooler and efficient filtration. 

The E900H portable compressor is powered by a 

214 hp premium efficiency TEFC electric drive motor with 

Wye-Delta starter. 

Sullair Corporation 

www.sullair.com 




Electric Motors & Drives 

Tapered roller 

bearings 

Baldor’s Dodge 

Type EXL tapered 

roller bearings provide 

misalignment 

and expansion capability, 

while maintaining 

industry standard 

Type E mounting 

dimensions. The 

design of the Dodge 

Type EXL incorporates 

a cartridge-style 

inner unit into a split ductile iron housing, which allows 

the inner unit to swivel freely in the hosing. The Dodge 

Type EXL offers a new bearing design with a 13% to 14% 

increase in load ratings. The roller bearings come in twoand 

four-bolt pillow blocks and utilize the same inner unit 

for expansion and non-expansion housings. 

Baldor Electric Co. 

www.baldor.com 

Adjustable frequency 

drives 

Eaton’s H-Max 

Series of adjustable 

frequency 

drives are 

equipped with 

HVAC software 

and hardware 

features, including 

an industryleading 

energy control algorithm. The H-Max Series has 

new technologies such as advanced dc capacitors and 

latest generation insulated gate bipolar transistors, with 

real-time clock and calendar. This gives customers the 

ability to design and operate efficient HVAC systems. The 

drives are available in 1.5 hp to 250 hp at 480 V and ¾ hp 

to 125 hp at 230 V. The H-Max Series comes with Ethernet, 

Modbus, N2, and BACnet built-ins. 


www.eaton.com 

Soft starter solutions 

The S811+/S801+ Soft Starters provide smooth acceleration 

and deceleration of the load with advanced monitoring, 

protection, and communication. The soft starters are 

designed for constant torque and variable torque applications. 

The soft starters come equipped with power and 

power factor monitoring capabilities, analog input, fault 

warnings, and integrated Modbus RTU communication. 

With the digital interface, users can configure, monitor, 

and enable protection. The soft starters are available in 

open and packaged control configurations with five frame 

sizes for currents ranging from 11 A to 1,000 A. 


www.eaton.com 

Split universal mounting kit 

The Split uKIT version of the AEGIS SGR Bearing Protection 

Ring protects the bearings of VFD-driven motors 

from electrical damage, and allows quick and easy retrofitting 

of the ring on virtually any ac motor shaft without 

decoupling attached equipment. The AEGIS Split uKIT is 

ideal for HVAC service contractors and plant maintenance 

departments. Designed to accommodate slingers, shaft 

shoulders, and other end bell protrusions, the kit comes with 

a split AEGIS ring, the halves of which are held together 

with a unique hinge. This hinge design allows the split 

AEGIS ring to be opened on one side, then closed and 

fastened together with built-in adhesive-backed aluminum 

tabs, providing rigidity to the assembled ring. 

Electro Static Technology Inc. 

www.est-aegis.com 


Line of actuators 

The Tritex II dc powered 

line of actuators 

integrates power and 

control electronics with 

brushless servo motors 

and actuators in one 

package. The actuators 

combine electric power 

with advanced thermal 

management modeling 

and maximize power in 

smaller packages without 

sacrificing performance. 

The Tritex II dc offers continuous forces of 1,000 lbs and 

1,300 lbs peak and speeds reaching 33 in./sec. The actuators 

have a wide range of I/O capabilities including digital 

I/O, analog I/O, and communication buses including Ethernet/IP, 

Modbus TCP, and PROFINET IO. With a wide 

range of applications including demanding environments, 

the actuators provide motion control in linear and rotary 

applications. 

EtherNet/IP enabled 

servo drive 

Exlar 

www.exlar.com 

The Allen-Bradley Kinetix 350 

single-axis EtherNet/IP servo 

drive offers a cost-effective entry 

in the Rockwell Automation Integrated 

Architecture system. This 

system scales from 200 to 10,000 

I/Os, allowing machine builders 

portability to migrate existing 

machine designs into new, higherend 

machine designs. The drive 

comes equipped with safe, torqueoff 

functionality allowing for tasks 

such as machine setup, cleaning, 

removal of jams, and other maintenance 

tasks. The Kinetix 350 

servo drive has 400 W to 3 kW 

of power range to meet global 

machine requirements. 



3 hp and 5 hp motors 

NovaTorque’s Gen2.0 PremiumPlus+ Electronically Commutated 

Permanent Magnet (ECPM) Motors are packaged 

in standard NEMA frame sizes and mounting dimensions 

for easy substitution. The motors are driven by variable frequency 

drives and boast motor-only rated point efficiencies 

of 93% and 92% for 3 hp and 5 hp versions. NovaTorque 

motors are available in the mounting frame size typical for 

induction motors in addition to one frame size smaller. The 

motors are compatible with readily available frequency 

drives from many leading manufacturers. 

NovaTorque 

www.novatorque.com 

Base drive solution 

The SINAMICS DC 

Master Base Drive is a 

prewired solution that 

comes with all the necessary 

components mounted 

onto a back panel. The 

drives are designed for 

end users and third parties 

such as system integrators 

and Siemens solution 

partners. Features of 

the SINAMICS DC Base 

Master Drive include input 

fuses, output dc fuses, a 

control transformer, ac line 

contractors, PROFIBUS, 

BOP20, UL508A certifications, and 65 kA SCCR rating. 

The new drives offer more power per panel in the same 

footprint compared to the previous two generations. 

Siemens 





Electric Motors & Drives 

Electrical Controls 

Base drive panels expansion 

The SINAMICS S120 drive system’s expansion includes 

PROFINET, Ethernet TCP/IP, and EtherNet/IP connectivity 

allowing for industrial Ethernet communication while offering 

innovative concepts for users wanting a single network 

for an entire plant. PROFIBUS DP and PROFINET are supported 

by the SINAMICS S120 drives to ensure seamless 

communications between all the components involved in 

an automation solution. The drives are designed to handle 

any drive requirement and facilitate vector, serve, and 

variable-frequency drive application with single or multiaxis 

offerings. 

Siemens 


Cabinet cooler system 

The Dual High Temperature Cabinet Cooler Systems 

purge and cool overheated electrical control panels in 

harsh environments. The cabinet coolers eliminate hightemperature 

malfunctions and protect sensitive electronics 

from hot, dirty locations by keeping electrical enclosures 

cool with air as cold as 20 F. With high cooling capacity of 

up to 5,600 Btu/hr, the cabinet coolers are designed for 

large electrical enclosures and high heat loads. The cabinet 

cooler applications include variable frequency drives, 

programmable controllers, industrial computers, motor 

controls, microprocessors, and robotics. 


www.exair.com 

CNC operator panel 

The SINUMERIK OP 019 is a CNC operator panel with 

advanced technology that enables seamless design integration 

to the SINUMERIK Operate graphical user interface. 

The design features a touchscreen operation including 

the new Power Control Unit 50.5 allowing high-speed key 

actuation. The OP 019 also features wide LEDs, which 

allow the user to clearly visualize every key actuation. The 

OP 019 panels provide basic machine display with three 

or four channels showing up to 13 axes. 

Siemens 


Sensing switch and transducer 

The ATS Current Sensing Switch and Transducer is a 

one-piece solution combing a limit alarm with an analog 

output signal transducer to monitor produced and consumed 

ac current up to 1,200 A while isolating outputs and 

input to maximize safety. The rotary switch makes it easy 

for operators to set the trip point. With an analog signal 

available at all times, increases or decreases in current can 

be detected. The switch also provides limit alarm contacts 

for over- or under-current conditions. 

NK Technologies 

www.nktechnologies.com 


Energy Management 

Device and data management 

The Foreseer X-Class software is designed to monitor, 

track, and analyze data from more than 100,000 devices at 

the same time across an enterprise. The software collects 

data and status information from power, environmental, 

safety, and security systems to help companies reduce 

energy consumption. The Foreseer X-Class software has 

a customized executive dashboard to help track and predict 

power usage trends and events, and improve energy 

efficiency. The software is designed for companies with 

global operations and a vast array of devices. 


www.eaton.com 

Gateway solution 

The Power Xpert 200E gateway is a solution that collects 

energy usage data from meters, allowing customers to 

benchmark energy usage, set energy management goals, 

determine the effectiveness of energy management initiatives, 

and reduce energy costs. The Power Xpert 200E 

gateway is designed to be used as a data acquisition tool 

for serially communicating energy meters via an embedded 

Web server or connecting to Ethernet-based applications. 

Eaton’s gateways can be used with the Power Xpert Energy 

Viewer, which provides a simple way to gather key energy 

parameters and display them in reports. 


www.eaton.com 

Consolidated 

complex data 

Power Xpert 

Reporting 3.0 

enables users to 

make sense of 

exhaustive power 

monitoring data and 

identify important 

statistics to improve 

efficiency and reliability. 

This software 

was designed for 

energy, healthcare, 

information technology, and facility managers to track and 

compare systems within facilities and across the enterprise. 

Power Xpert Reporting is equipped with 13 ready-to-go 

report templates with graphics and charts to help users 

understand and control critical power systems and energy 

flow. The new version of Power Xpert Reporting allows 

users to create custom reports with user-selectable or 

virtual attributes and complex formulas for custom data. 


www.eaton.com 

Data logger 

EXAIR’s Digital Flowmeter is designed to monitor compressed 

air consumption and waste. With EXAIR’s newly 

added USB Data Logger, users can maintain a history of 

the Digital Flowmeter’s measurements for analysis. The 

information from the data logger can be removed from the 

Digital Flowmeter and plugged into a computer where the 

data can be viewed. The Digital Flowmeter comes with 

an optional Summing Remote Display to allow for easy 

monitoring of compressed air consumption in any location. 


www.exair.com 




Energy Management 

Environmental Health 

Dock seal 

The Insulator Dock Seal with Light-Blocking Header is a 

durable dock seal that closes small light gaps caused by 

trailer protrusions. The design of the Insulator Dock Seal 

features rows of layered, horizontal pleats that conform to 

the protrusions as a trailer backs in. All of Frommelt’s dock 

seals are reinforced with high-strength Durathon fabric over 

a flexible vinyl base fabric to protect against wear and tear. 

The corners of the Insulator Dock Seal are also reinforced 

with layers of Durathon fabric and flexible high-molecular 

weight polyethylene sheeting to prevent damage and are 

attached with industrial Velcro for quick replacement. 

Frommelt Products Corporation 

www.frommeltsafety.com 

Ultra-fine atomized misting system 

The AirGo Misting System fan is available with highfiltered 

misting, producing a cooling effect equivalent to 

22 tons of air conditioning. The system’s design features 

an ultra-fine atomized mist that absorbs heat in the air 

and allows for a safe cooling zone in hot outdoor settings. 

The fan produces the cooling power of air conditioning in 

any setting. The AirGo Misting System provides a cooling 

breeze measured at 140 ft and about 6,000 sq ft of floor 

coverage area. 



Power protector 

The 300 kW VDC-XE with 

High Current (HC) option is a 

solution for protecting powerdependent 

applications in facilities 

that do not have the floor 

space for multiple backup units. 

Compatible with all major brands 

of 3-phase UPSs, the VDC-XE 

with HC option connects to the 

dc bus of a UPS. The system 

includes patented technology 

consisting of a flywheel hub 

formed from aerospace-grade 

steel, a high-speed permanent 

magnet motor generator, a contact-free 

magnetic levitation system, 

and a touchscreen graphical 

display. VYCON’s flywheels 

incorporate a host of advanced features that make the 

systems easy to use, maintain, and monitor. 

VYCON Inc. 

www.vyconenergy.com 

Mercury 

adsorbent 

The VaporLokCapture 

is a breakthrough technology 

that adsorbs mercury 

vapors from broken lamps 

within lamp storage, shipping, 

or recycling containers. 

The VaporLokCapture 

is featured in VaporLok’s 

fluorescent lamp shipping 

and recycling system. The 

design minimizes the risk 

of exposure to mercury by 

reducing 95% of the vapor within a container. The Vapor- 

LokCapture is manufactured with powdered activated 

carbon and inert chemicals, which immediately capture 

mercury vapor when lamps or compact fluorescent lamps 

(CFL) break. The product will be incorporated into industrial 

products of VaporLok and consumer CFL packaging 

solutions. 

VaporLok Products 

www.vaporlokproducts.com 


Fluid Handling 

Fluid recycling 

solution 

The mobile 

SumpDoc by Eriez 

provides complete, 

inline fluid recycling 

for machine tools 

operating in three 

simple steps. The 

operator selects 

each mode starting 

with Sump Vac 

mode, moving to 

Filtration Mode 

and then to Coolant 

Makeup Mode. 

When the sump tank 

reaches the desired concentration level, the process is 

complete. The SumpDoc is completely portable, allowing 

operators to drop in the hoses, complete a full cycle, and 

move on to the next machine tool sump or parts washer 

to be cleaned. 

Eriez 

www.eriez.com 

Siphon fed 

spray nozzles 

EXAIR’s Atomizing 

Spray Nozzles atomize 

fluids in a range 

of spray patterns by 

combining liquid and 

compressed air to 

create a mist of atomized 

liquid that can be 

easily adjusted to various 

applications. The 

siphon fed nozzles 

require no liquid pressure 

and can be used 

with gravity fed liquids 

or lift liquids from a 

siphon height as much 

as 36 in. Siphon fed nozzles can be used on liquids with 

a viscosity up to 200 cp. The nozzles are fully adjustable 

with a stainless steel construction for durability and corrosion 

resistance. 


www.exair.com 

Inline vortex 

flowmeter 

The VLM10 combines 

an inline vortex meter, 

a built-in flow computer, 

and an integral temperature 

sensor giving 

users an elegant all-inone 

solution for their 

metering needs. The 

VLM10 is precise and 

reliable with a steam or 

gas mass flow accuracy 

of ± 1.5% over a wide 

20:1 flow range. The 

fully welded, no-gasket 

design ensures safe 

measurement of steam 

and allows the sensors 

and RTD to be removed without having to shut down the line 

first. The built-in Web server allows customers to monitor 

flow and monitor meter health through the Internet. 

Spirax-Sarco Inc. 

www.spiraxsarco.com 

Threaded port 

connectors 

FasMate FN Series 

connectors allow for 

quick, easy connections 

to threaded 

ports, delivering 

results in many applications. 

The connectors 

feature easy 

actuation and a split 

collet design. The 

versatile connectors 

have the capacity to 

perform three styles of actuation: squeeze level, pneumatic 

pilot, and pneumatic thumb valve. The new series offers 

additional features and benefits for better performance 

and durability. The FasMate FN Series provides increased 

application compatibility through the connectors that offer 

an extensive threaded port sealing range of 1/8 in. to 1/2 in. 

NPT. The connectors are equipped with pressure-assisted 

sealing technology to eliminate the risk of separation. 

FastEST Inc. 

www.fastest-inc.com 




HVAC 

Airfoil fan system 

Big Ass Fans’ Powerfoil X2.0 system combines patented 

airfoils and winglets with AirFence technology to increase 

the overall coverage. The winglet improves airfoil effectiveness 

through the elimination of turbulence at the tip, 

while the AirFence is able to capture air that would have 

slipped off the end of the airfoil. The Powerfoil X2.0 offering 

a 28% increase in coverage area is available in 8 ft to 

24 ft diameters. 



Modulation infrared heater 

The MP Series of modulation infrared 

heaters allow users to select a desired 

operation for their specific needs through 

the incorporation of three performance 

curves, as well as a Blast Mode. The Blast 

Mode allows users to temporarily lock the heater into its 

highest input with an extra 5,000 BTU for extreme environmental 

demands. The models available in the MP Series 

range from 80,000 BTU to 200,000 BTU. The MP Series 

features full gas modulation with corresponding airflow 

modulation to allow for optimal fuel utilization. 

Detroit Radiant Products Co. 

www.re-verber-ray.com 

Portable and 

adjustable fan 

The Renegade 

Series of HVLS fans 

are designed for 

improving air circulation 

in areas with 

overhead obstructions 

or limited ceiling 

access with a floormounted 

configuration. 

The HVLS fans 

are portable and can 

be moved when necessary 

and are also 

adjustable from 10 ft 

to 15 ft in height. The 

Renegade fans are 

designed with Rite- 

Hite’s Propell-Aire custom aluminum blades with a single 

unit circulating air covering up to 7,850 sq ft. The fans are 

available in 8 ft, 12 ft, and 16 ft diameters with optional 

SureStop Safety Barriers to protect against accidental 

contact. 

Rite Hite Holding Corp. 

www.ritehite.com 

Steam system software 

Steam DesignPro 6.1 was designed to meet the demands 

of mechanical engineers, designers, and contractors in the 

HVAC market. The software was created as a visual design 

tool through an easy, drag-and-drop method for designing 

and modeling HVAC steam systems. The Windows-based 

software allows for easy modeling of steam generation, 

steam distribution, steam utilization, and condensatehandling 

systems. Steam DesignPro supports compiling 

of equipment schedules based on the Spirax Sarco catalog. 

Additional features include the ability to select relief 

valves, flowmeters for steam and hydronic applications, 

and control valves. 

Spirax-Sarco Inc. 

www.spiraxsarco.com 


Lighting 

Color-consistent LED 

Columbia Lighting’s e•poc LED uses precise standards 

to maintain superior color consistency within each fixture 

throughout its lifetime. The luminaires are passed through 

a test booth where each receives a QR code capturing the 

exact initial color, lumen rating, and module serial number 

creating the best quality and the most traceability of LED 

lighting. The e•poc LED is constructed from 70% recycled 

steel and has a 50,000-hr, mercury-free lamp life. The 

e•poc LED provides reduced energy consumption when 

higher light levels are not necessary through the two lumen 

output configurations available. 

Columbia Lighting 

www.columbialighting.com 

Architectural luminaire 

As part of Columbia Lighting’s createchange series, 

the Serrano Architectural Luminaire is a three-element 

diffuser combining a performance-optimized center optic 

with two high-transmission, lenticular side lenses to provide 

efficiency. Serrano delivers energy savings of up to 

40% while maintaining lighting quality and light levels. The 

Serrano is compatible with a variety of controls and has a 

wiHUBB-enabled option to integrate with Hubbell Building 

Automation’s wireless mesh network. 



Architectural 

LED 

The Serrano LED 

delivers high efficacies 

up to 101 

lumens per watt 

and a fixture life of 

up to 50,000 hours 

at 80% lumen maintenance. 

Serrano 

LED is compatible 

with a variety of controls and can be ordered with wiHUBB 

capability to easily integrate with Hubbell Building Automation’s 

wireless mesh network. The modular plug-and-play 

design allows for components to be easily swapped out as 

technology advances. To ensure color consistency, each 

Serrano LED is tested to maintain a three-step MacAdam 

ellipse. 



Emergency LED lighting 

The EV Series LED emergency light utilizes two highpowered 

long-life LEDs to produce superior light output with 

optimized fixture spacing of 27 ft. The EV Series emergency 

lights require less than 2 W to power and utilize an environmentally 

friendly nickel metal hydride (NiMH) battery. 

The EV Series measures only 8.5 in. wide by 5 in. high 

with fast wall mount installation. The LEDs are mounted 

inside a die-cast housing, utilizing precious components 

to offer adjustability and thermal stability. 

Dual-Lite 

www.dual-lite.com 




Lighting 

Heavy industrial LED 

Hubbell Industrial’s LED Highbay is engineered for 

tough industrial environments, offering a customized 

solution in an eco-smart and retrofit-ready package. 

The design features a rugged cast aluminum housing 

design with a hinge and latch-mounting system. The LED 

Highbay’s design also features custom engineered LED 

optics for evenly distributed 5,000 K light in aisle, narrow, 

and wide distributions for use in up to 45 C ambient 

temperature environments. The LED Highbay comes 

standard with 0 V to 10 V dimmable drivers and can 

produce up to 100 lumens per watt with a life span of 

100,000 hours. 

Hubbell Industrial Lighting 

www.hubbellindustrial.com 

Surface mount luminaire 

Hubbell Industrial’s Sedona LED Surface Mount luminaire 

is designed to provide a unique, high-performance illumination 

solution for surface ceiling mount and parking garage 

applications. The Sedona LED features a hexagonal LED 

cluster design that provides optical flexibility and light level 

scalability. The packages available in this luminaire provide 

92 to 100 lumens per watt with an ambient temperature of 

40 C. The Sedona LED is wet-location listed and offers 

complete on/off dimming operation. 

Hubbell Industrial Lighting 

www.hubbellindustrial.com 

Commercial, industrial LED luminaires 

The AccuLite Highbay and Lowbay LED Luminaires are 

low-profile industrial LED luminaires ideal for large commercial 

and industrial spaces. The fixtures are equipped with 

several innovative features including the large-format LED 

chip technology, hybrid TIR/reflector optics, and an ultra-thin 

efficient housing design. These features offer higher efficacy 

with improved thermal performance and ability to drive the 

LED more efficiently at higher currents. The LED luminaires 

produce up to 34,000 lumens of uniform area illumination 

and efficacies approaching 100 lumens per watt. The fixtures 

provide 57% energy reduction with a 100,000-hr lamp life. 

Juno Lighting Group 

www.junolightinggroup.com 


Maintenance Tools & Equipment 

Heavy-duty 

gear oils 

The Mobil 

SHC Gear 

Oil Series are 

heavy-duty gear 

oils designed for 

enclosed gearing, 

as well as 

plain and rolling 

element bearings. 

The series 

is designed to 

provide service in equipment protection, oil life, and problem-free 

operation, enabling increased customer productivity. 

The lubricants are formulated from synthetic base 

fluids with exceptional oxidation and thermal properties. 

The Mobil SHC Gear Series covers a viscosity range from 

ISO VG 150 to 6800, which allows the series to meet the 

lubrication needs of very slow speed and high-load/hightemperature 

gears and bearings. 

Exxon Mobil Corp. 

www.exxonmobil.com 

Power quality 

analyzers 

The Fluke 430 Series 

II three-phase power 

quality analyzers use 

patented algorithms to 

measure energy waste 

and quantify costs. By 

providing the ROI justification 

to mitigate 

power quality distortion, 

the 430 Series II 

helps reduce electrical 

power consumption and 

improve the performance and lifespan of electromechanical 

equipment. With the Unified Power function of the 430 

Series II, electricians, utility technicians, electrical engineers, 

field service technicians, and energy consultants can 

determine how much power is being wasted and calculate 

the extra consumption costs. The improved screen quality 

and battery life on the 430 Series II gives users more 

options to analyze power quality and power consumption. 

Fluke Corp. 

www.fluke.com 

Vibration 

screening tool 

The Fluke 805 Vibration 

Meter is a portable multifunction 

vibration screening 

tool, providing quantifiable 

information on the bearing 

and health of motors and 

other rotating equipment. 

The Fluke 805 has the ability 

to measure overall vibration, 

bearing condition, and 

surface temperature. The 

design of the Fluke 805 

features a unique sensor 

tip that minimizes measurement 

variations caused by 

device angle or contact 

pressure, reducing operator 

error and improving accuracy. 

The vibration meter also has a severity scale for overall 

vibration and bearing condition. 

Fluke Corp. 

www.fluke.com 

Infrared cameras 

Fluke’s Ti Series of infrared 

cameras or thermal imagers 

offer a broad range of easyto-use 

capabilities, capturing 

images of infrared energy or 

temperature. Fluke infrared 

cameras combine the power 

of infrared images with visible 

light images on the same 

display. The thermal imaging 

detects heat patterns or temperature 

changes in objects, 

allowing users to discover 

problems or monitor developing 

problems. Common applications 

of the Ti Series include 

electrical, mechanical, process, 

and building inspection. 

Fluke Corp. 

www.fluke.com 




Maintenance Tools & Equipment 

Machinery alignment 

ROTALIGN Ultra iS is a system designed by 

Prüftechnik for machinery alignment, combining 

sensALIGN intelligent sensor technology with 

ROTALIGN Ultra computer for fast acquisition and 

real-time results display. sensALIGN calculates misalignment 

from collected measurement points while 

monitoring the rotating angle, speed, acceleration, 

and environmental vibration. This eliminates external 

influences and coupling backlash, ending in accurate 

readings in harsh conditions. With ROTALIGN Ultra 

iS, users can accomplish alignment in three steps: 

enter dimension, measure, and view results. 

Prüftechnik Group 

www.prueftechnik.com 

Inspection system 

The SeeSnake MAX rM200 Camera System combines portability 

and versatility to provide plumbing professionals with a solution 

for inspecting longer and tighter lines up to 200 in. in length 

and 1-1/2 in. to 6 in. in diameter. The camera system features 

improved reel mechanics for easier passage through tight turns, 

an ultracompact camera capable of providing optimal lighting 

through narrow spaces, and an upgraded cable. This provides 

greater abrasion resistance and allows users to push further with 

less effort. The system comes equipped with a built-in docking 

system for attaching viewing monitors and is compatible with 

RIDGID SeeSnake CS10 and CS1000 digital recording monitors. 

RIDGID 

www.ridgid.com 

Warning beacon 

The wireless aisle-way beacon is a pushbutton and 

motion sensing technology providing users with the flexibility 

to position aisle-way beacons when and where they 

are needed. This allows plant operators to signal for parts, 

material refills, or machine maintenance in a timely manner. 

The design of the beacon allows for one, two, or four 

wireless pushbuttons to be linked. The motion sensor can 

be linked to the beacon for visible warning of approaching 

industrial vehicles, and the ultrasonic sensor can be linked 

for blind doorway applications. 




Materials Handling Systems 

Air caster 

The LoadRunner makes it safe for one operator to easily 

move loads up to 2,500 lbs on air by utilizing an on-board 

compressed air caster to float a load across the floor. The 

self-contained unit features a low-profile deck with a 2–in. 

insertion height and throttle-style fingertip controls. The 

LoadRunner can assist or replace traditional equipment 

such as hand trucks, pallet jacks, and forklifts. The Load- 

Runner unit is emission free and designed for manufacturing, 

cleanrooms, assembly, testing, and warehouse 

applications requiring load movement. 

AeroGo Inc. 

www.aerogo.com 

Tire lift trucks 

Cat Lift Truck’s 2EPC5000-2EP6500 Series is equipped 

with powerful ac technology, featuring improved energy 

efficiency, performance levels, and premium operator 

ergonomics. The model gives users the ability to run up 

to two shifts on one battery charge in most applications. 

The 2EPC5000-2EP6500 Series is equipped with sealed 

wet-disc brakes, electrical components, and connectors, 

providing added protection for harsh environments. The 

enhanced operator control features an adjustable compartment 

and standard fingertip hydraulic control with an 

optional enclosed cabin for protection in cold or wet environments. 

Cat Lift Trucks 

www.cat-lift.com 

Chain hoist 

The Lodestar Electric 

Chain Hoist incorporates 

features that provide 

steady lifts for a variety 

of applications. The 

hoist is designed with a 

lightweight, durable cast 

aluminum housing and a 

powder-coasted finish for 

high visibility. The Lodestar 

Electric Chain Hoist 

has a capacity range of 

1/8 to 3 tons and a wide 

range of speeds creating 

versatility. The control 

panel of the hoist allows 

for quick voltage change, 

access to terminal strips, 

and simple fuse installation. The adjustable limit switch 

prevents the load from over-travel and built-in overload 

protection helps prevent lifting of dangerous overloads. 

Columbus McKinnon Corporation 

www.cmworks.com 

Electric end rider 

The Jungheinrich ECR 327/336 Series of electric end 

rider pallet trucks, available in 6,000 lbs and 8,000 lbs, 

incorporate a variety of applications including order picking, 

long distance transporting, and loading/unloading trailers. 

Designed for durability, the ECR Series features thick forks 

with a cast steel frame and sealed electrical components. 

The riders come equipped with standard features such as 

an electromagnetic brake, advanced regenerative braking, 

and adjustable casters. An optional corrosion protection 

package provides a galvanized coating on key components, 

resulting in durability in wet and corrosive environments. 

Jungheinrich 

www.jungheinrich-lift.com 




Materials Handling Systems 

Eco-performance 

truck series 

The 7000 Series Reach-Fork Trucks 

feature economic and ecological 

benefits, maximizing the number of 

pallets that can be moved per hour. 

This includes regenerative lowering 

that produces energy when the forks 

are lowered to increase battery shift 

life. The trucks were designed with an 

A-frame suspension with strong steel 

springs to provide a strong connection 

between the wheels and frame. They 

also feature an exclusive steered idler 

wheel, eliminating caster snap, and 

full-time traction and steering. 

The Raymond Corp. 

www.raymondcorp.com 

Galvanized pallet trucks 

Toyota’s three models of ac electric pallet trucks and 

walkie riders feature a Galvanized Chassis option to protect 

the vehicles while operating in wet environments. The 

three models include the 8-Series ac electric walkie pallet 

truck, 8-Series end-control walkie rider, and 7-Series electric 

walkie pallet truck. The chassis is designed for users 

who move materials in and out of cold storage facilities, 

the chemical, salt and brine industries, or in areas where 

frequent wash-down is required. Other features include 

heavy-duty Teflon coated Polytube bushings; galvanized 

metal frames; corrosion-resistant linkage pins; and galvanized 

lower linkages, pull rods, and connecting links. 

Toyota Industrial Equipment 

www.toyotaforklift.com 

Material handling 

workhorses 

The 8000 Series pallet 

trucks are material handling 

workhorses that 

stand up to tough applications 

while maximizing 

productivity and contributing 

to sustainable 

operations. The design 

of the pallet trucks features 

increases in material 

strength, enabling 

them to meet heavy-duty 

application needs. With 

PowerSteer, the trucks 

reduce steering efforts 

by up to 90% and provide 

speed-sensitive steering for smooth control at all speeds. 

The trucks offer a number of user-friendly features including 

roomy operator compartments, accessory bars, large 

storage totes, and additional caster options. 

The Raymond Corp. 

www.raymondcorp.com 


Power Transmission 

Operator safety 

switchgear 

Eaton Corporation’s Arc- 

Resistant Front-Accessible 

Switchgear provides centralized 

control and protection 

for low-voltage power 

distribution equipment and 

is engineered to enhance 

operator safety. The front 

accessible design minimizes 

equipment footprint 

for utility, industrial, data 

center, institutional, hospital, 

and water facilities. The 

design also allows the equipment to be installed against the 

wall and eliminates the need to meet the National Electrical 

Code requirement of 36 in. of rear clearance. With an 

optional ANSI Type 2B rating for the front-accessible arcresistant 

switchgear, the operator can be protected while 

the low voltage control or instrumentation compartment 

doors are open. 


www.eaton.com 

Drawout switchboard, panelboard 

Eaton Corporation’s 2- and 3-pole molded case circuit 

breakers (MCCB) provide front-accessible and frontconnected 

equipment with ease of maintenance. Drawout 

feeder MCCBs are available in 20 A to 600 A. The drawout 

MCCB switchboard and drawout MCCB panelboard may 

be submitted for almost any application. Breakers on the 

drawout MCCB units are inserted and removed through 

a mechanical removal system similar to other drawout 

designs associated with switchgear. For greater density 

and reduced space, the breaks are horizontally mounted 

in a traditional panelboard group mounted way. 


www.eaton.com 

Grid-connect 

inverters 

Utility-scale inverter 

The Power Xpert Solar 1,500 kW Inverter is designed to 

improve plant levelized cost of energy, maximize energy 

harvest, operate in harsh environments, and adhere to 

safety standards. The inverter for utility-scale, solar applications 

converts dc power into clean ac. Eaton created 

the inverter to use an MV pad-mount transformer, which 

is connected to the inverter via a direct-coupled throat 

connection, reducing cable requirements, pad size, and 

commissioning time. The Power Xpert Solar 1,500 kW 

features a wide Maximum Power Point Tracking voltage 

range, which maximizes inverter operation time to boost 

energy harvest. 


www.eaton.com 

Eaton Corporation’s 

Series 6001 

Energy Storage 

Grid-Connect 

Inverter features 

proprietary electronics 

and provides 

improved 

stability for wind 

and solar energy 

customers. The inverter is designed to allow users to 

achieve full battery storage potential because of a large 

dc operating voltage window. With a 20-year life for utility 

applications, the Series has rated magnetic, liquid-cooled 

power modules with over seven million hours mean time 

between failure and a rugged enclosure for harsh environments. 

The Series inverter provides the required grid 

support, including low-, zero-, and high-voltage range, 

stand-alone/black start operation, islanding detection, utility 

communication, and full four quadrant operation. 


www.eaton.com 




Power Transmission 

Mid-size bevel speed reducers 

The new upgraded series is a mid-sized family of right 

angle spiral bevel speed reducers and gearmotors. The 

Cyclo BBB4 has a combination of features that results in 

a highly reliable, efficient, and durable gearbox. The allsteel 

internal construction, featuring Cyclo or planetary 

inputs and the ductile iron housing, provides unmatched 

ruggedness. Interchangeable with the Cyclo BBB3 series, 

the redesigned Cyclo BBB4 series has been optimized for 

increased power ratings. A new F size yields higher torque 

and accommodates larger shaft diameters. Sumitomo also 

introduces 46 new standard ratios, along with 87 optional 

ratios with this generation of Cyclo BBB4. 

Sumitomo Machinery Corp. of America 

www.smcyclo.com 

Bevel speed reducers 

The new Cyclo BBB5 series is a compact, energy-efficient 

family of right angle spiral bevel speed reducers and 

gearmotors. This series has been optimized for direct shaftmounted 

applications. Similar to the Cyclo BBB4 Series, the 

Cyclo BBB5 has a combination of features that results in a 

very reliable gearbox. The all-steel rotating components, 

featuring Cyclo or planetary, exclusive bevel outputs, and 

compact housing design provide top performance without 

thermal limitations. To enable customers to precisely define 

operating speeds, Sumitomo introduces more than 100 

ratios with this new 5 series of Cyclo BBB. 

Sumitomo Machinery Corp. of America 

www.smcyclo.com 

Electric linear actuator 

Thomson WhisperTrak Electric Linear Actuators maximize 

design flexibility and improve performance and user comfort 

in personal mobility, rehabilitation, and medical equipment 

applications where reliability, small size, and low noise are 

design considerations. The actuators comply with all relevant 

certificates and are built in accordance with ISO 9000. A 

sealed, IP67 enclosure allows the electric linear actuator to 

provide maintenance-free operation throughout its lifetime. 

The actuators are rated to provide at least 10,000 cycles at 

maximum load. The actuators operate at 12 Vdc or 24 Vdc 

and can handle static and dynamic loads up to 2,000 N at 

speeds up to 5.8 mm/sec. 

Thomson Industries Inc. 

www.thomsonindustriesinc.com 


Productivity Training Software 

Blended 

learning 

solutions 

GPAllied’s 

inspired Blended 

Learning is 

designed to 

allow participants 

to take 

control of their learning experience through instructor ledclasses, 

online curriculum, and skill applications within their 

facility or industrial environment. The training is a three-step 

process including a learning project kickoff, eLearning, and 

practical application. GPAllied inspired Blended Learning 

enables organizations to expand the capabilities of existing 

maintenance and reliability engineers and develop new 

maintenance and reliability engineers to meet growing 

needs. GPAllied employs its Rapid Improvement Process 

throughout the blended learning experience to ensure 

retention, alignment, and lasting change. 

GPAllied 

www.gpallied.com 

Test question 

scrambler 

The newly developed 

Scramblizer 

by Ramsay Corporation 

allows online 

administration of 

test questions in a 

randomized order, 

so each test taker 

sees a different 

arrangement of 

test questions. The 

scrambling of test 

questions discourages cheating while allowing the use 

of computers in close proximity. With each test showing 

the questions in a different sequence, memorization of 

answers is discouraged in order to avoid communicating 

those answers to others. The tests are machine-scored 

without the possibility of hand-scoring errors. With the 

answers on each item reported in their original order, test 

administrators can easily compare test-takers’ results. 

Ramsay Corporation 

www.ramsaycorp.com 

System 

monitoring 

mobile 

application 

Performance and visibility software 

FactoryTalk VantagePoint 4.0 Software is designed 

to simplify the end-user experience, include connectivity 

to additional Rockwell Automation products, and provide 

native integration to Microsoft SharePoint 2010. The software 

lets users expose plant floor data to the enterprise and 

provides capabilities like business intelligence, collaboration, 

and communications. The software connects real-time, 

historical, relational, and transactional data sources to 

create a single resource that can access, aggregate, and 

correlate information into a common, unified model. The 

Web-based dashboards and reports monitor key performance 

indicators and help empower users at every level of 

an enterprise to better manage their operation in real time. 



Tango Mobile 

Rounds Logging software 

designed for a 

smartphone or tablet 

allows reliability 

information management 

to take place in 

real time and in process. 

Tango Mobile 

Rounds Logging is 

an economical way to involve operators and mechanics 

in a plant’s reliability program. Numeric readings can be 

set for low and high alarm levels. Tango QR codes can be 

installed on equipment by plant personnel, contractors, 

or repair vendors. Users can quickly scan a QR code with 

Tango Mobile and instantly view condition monitoring history, 

equipment repair history, equipment design details, 

and linked documents. 

24/7 Systems Inc. 

www.tf7.com 




Safety 

GE AK-1/2-50 remote racking system 

CBS ArcSafe offers a single application Remote Racking 

System for GE AK-1/2-50 extraction-style power circuit 

breakers. The RRS-3 AK-1/2-50 system enables operators 

to install and remove GE AK-1/2-50 equipment from up to 

150 ft away with the wireless remote control. Installation 

of the RRS-3 AK-1/2-50 requires no modifications to the 

breaker or switchgear. This lightweight and portable system 

is ideal for hard-to-access areas including mezzanines, 

basements, and other areas with space restrictions. 

CBS ArcSafe 

www.cbsarcsafe.com 

Square D VR 

remote racking 

system 

CBS ArcSafe has 

developed a single 

application Remote 

Racking System for 

Square D VR-style 

power circuit breakers. 

The RRS-3 VR system 

allows operators to 

install and remove this 

style of circuit breaker 

from up to 150 ft 

away using a wireless 

remote control. The 

user-friendly RRS-3 VR requires no modifications to the 

breaker or switchgear and may be installed by one person 

in a matter of seconds. This lightweight and portable system 

is ideal for mezzanines, basements. and other locations 

with space restrictions. 

CBS ArcSafe 


Rotary remote 

racking system 

The CBS ArcSafe RRS-4 

Remote Racking System is 

an upgraded version of the 

RRS-1 for rotary-style power 

circuit breakers. The RRS-4 

boasts many of the same 

components as the RRS-1 

unit, making it portable, 

adjustable, and user-friendly. 

The RRS-4 is operated 

using a dual mode, source 

programmable, PLC-based 

control system. This PLCbased 

control system offers 

two operating modes: CCM 

Mode, allowing users to 

monitor the drive motor running 

current, and SEK Mode, 

allowing users to monitor the 

drive motor revolution count. Users have an option of which 

control mode to choose and can switch between the two. 

CBS ArcSafe 


DHP remote switch actuator 

The RSA-11A is a remote switch actuator for Westinghouse 

DHP power circuit breakers. This product allows 

operators to remotely close and/or trip the circuit breaker. 

Installation of the lightweight and portable RSA-11A may 

be performed by one person in a matter of seconds and 

requires no modification to breaker or switchgear. 

CBS ArcSafe 



DS remote switch actuator 

The RSA-12A is a remote switch actuator that remotely 

operates all styles of DS power circuit breakers. The RSA- 

12A is designed to operate on equipment with either manual 

or electric charging mechanisms and is compatible with 

all manufacturers and sizes of DS breakers. This product 

enables operators to charge, close, and/or trip the circuit 

breaker. Installation of the lightweight and portable 

RSA-12A requires no modification to existing breaker or 

switchgear. 

CBS ArcSafe 


GE AK-1/2-25 remote switch actuator 

The RSA-29 is a remote switch actuator for GE AK-1/2- 

25 power circuit breakers. This product allows operators 

to remotely charge, close, and/or trip the circuit breaker 

from up to 150 ft away when using a wireless remote control. 

Installation of the lightweight and portable RSA-29 

may be performed by one person in a matter of seconds 

and requires no modification to breaker or switchgear. 

The RSA-29 is powered and operated by a CBS ArcSafe 

Remote Switch Operator (RSO-IIID). 

CBS ArcSafe 


Bidirectional 

disconnect 

switches 

Eaton’s bidirectional 

disconnect switches 

incorporate the latest 

switching technology 

to enhance operator 

safety, extend 

equipment life, and 

reduce installation 

costs in grounded and 

ungrounded systems. 

The bidirectional disconnect switches can switch one circuit 

per pole and remove polarity limitations. The switches 

are available at 30, 90, and 100 A, with either 600 Vdc or 

1,000 Vdc configurations. These new switches are available 

for either grounded or ungrounded PV systems and 

are capable of breaking up to six circuits with one switch. 

Grounded system switches include individual, isolate terminals 

for landing the grounded conductors. 


www.eaton.com 

Medium-voltage 

vacuum circuit 

breaker 

The W-VACiMB 

medium-voltage vacuum 

circuit breaker is 

designed for mining 

applications and engineered 

to provide reliable 

and robust circuit 

protection in a compact 

and reliable package. 

The breakers are also 

designed to protect transformers, capacitor banks, motors, 

busbar sections, and cable. To protect from demanding 

environmental conditions, the breakers are sealed from 

dust and contaminants prevalent in the mining industry and 

are suitable for high altitude, shock, vibration, and high 

temperatures. The 17.5 kV circuit breakers make and break 

power in a sealed environment with no external arcing. 


www.eaton.com 




Safety 

Dock warning 

signal alarm 

The Safety Sentry 

Warning Signal Alarm 

improves loading dock 

safety by alerting those 

nearby a vehicle backing 

into the dock position. 

The Safety Sentry utilizes 

a 105 dB siren and 

strobe light combination 

system with industrial 

motion sensing technology. 

The patent-pending 

design is rated NEMA 4 

and constructed with UVresistant 

polycarbonate 

using liquid tight strain 

relief connections. 

Erich Industries Inc. 

www.erichindustries.com 

Automated barrier door 

The Guardian Defender combines safety interlock 

switches/controls capable of achieving up to PLe, Category 

4 level safety with a movable physical barrier restricting 

access to dangerous machine movement. At the same 

time, process driven hazards such as weld flash, sparks, 

flying debris, mist, spray, and smoke are contained. The 

Guardian Defender’s switches/controls provide clear visual 

communications with two signals, green for safe and red 

for unsafe. The machine is designed with a 9-in. foam soft 

bottom edge and Armorplex curtain material. 

Frommelt Safety 

www.frommeltsafety.com 

Swing arm system 

The Tether Track Swing Arm Fall Arrest System protects 

workers from injures due to falls. The system provides 

workers with a high degree of mobility and freedom, while 

preventing falls to lower levels. The Swing Arm System 

provides circular or semicircular fall protection with a 

compact footprint. The swing arm can be positioned over 

the workspace when needed and moved out of the way 

when not in use. The track can be wall mounted, column 

mounted, or stand alone and is available in standard arm 

lengths from 8 ft to 30 ft. 

Gorbel Inc. 

www.gorbel.com 

Safety valve 

Cormack Propane Safety Valve helps prevent LPG 

escaping when changing forklift cylinders. When the Cormack 

valve is closed, it shuts off LP Gas next to the coupler 

to prevent it from coming through if the seal fails. If the 

Cormack valve is open, the foolproof handle design covers 

the coupler so the operator cannot disconnect it in the open 

position. The Cormack valve fits almost all forklifts and 

increases LPG cylinder exchange safety. With installation 

only taking minutes, LPG cylinder changes are quicker. 

Liftow Limited 

www.liftow.com 


Metal detectable 

components 

DETEX Belt Dressing is a 

metal detectable plastic aerosol 

component for the food industry, 

designed to assist food processing 

plants in meeting strict 

HACCP requirements. Blue 

colored caps, actuators, and 

extension tubes signify the components, 

which are metal detectable 

and can help prevent food 

from being contaminated. All 

metal detectable plastic component 

ingredients are GRAS listed, 

meeting the FDA requirements 

as an acceptable material for use 

in food processing plants. The 

aerosol can is in compliance with 

the Food Safety Net Services 

and contains lithographed labels. 

LPS Laboratories 

www.lpslabs.com 

Versatile lubricant 

DETEX Clear Penetrating 

Grease is a high-performance, 

versatile lubricant fortified with 

PTFE additives for enhanced 

lubrication. Clear Penetrating 

Grease is NSF Registered H1 

No. 143804 and packaged with 

DETEX, metal detectable plastic 

components. DETEX components 

can be identified using 

standard metal detection equipment 

should they become loose 

in the processing area. DETEX 

chemicals protect vital machinery, 

as well as protect against 

expensive recalls, costly downtime, 

and damaged reputations. 

DETEX products are ideal for use 

in food manufacturing, processing, 

and packaging facilities. 



Water-resistant 

lubricant 

DETEX Food Grade Chain 

Lubricant is a water-resistant 

lubricant designed primarily for 

the effective lubrication of all 

types of chains and conveyors 

operating in food environments. 

Food Grade Chain Lubricant is 

NSF Registered H1 No. 132899 

and packaged with DETEX, metal 

detectable plastic components. 

DETEX components can be 

identified using standard metal 

detection equipment should they 

become loose in the processing 

area. DETEX chemicals protect 

vital machinery, as well as protect 

against expensive recalls, 

costly downtime, and damaged 

reputations. DETEX products are 

ideal for use in food manufacturing, 

processing, and packaging 

facilities. 



Lubricant and 

penetrant 

DETEX Food Grade Machine 

Oil is a lubricant and penetrant 

that minimizes friction, extends 

equipment life, and penetrates to 

provide complete surface coverage 

protection against wear and 

corrosion. Food Grade Machine 

Oil is NSF Registered H1 No. 

129000 and packaged with 



















Safety 

Anti-stick agent 

DETEX Food Grade Silicone 

Lubricant is a nonstaining, highquality 

lubricant designed especially 

for the food industry for use 

as an anti-stick agent for chutes 

and slides. Food Grade Silicone 

Lubricant is NSF Registered H1 

No. 113815 and packaged with 














Water-based lubricant 

DETEX Heavy-Duty Silicone 

Lubricant is a unique waterbased 

formulation that contains 

a high percentage of silicone for 

better and longer lubrication. 

Heavy-Duty Silicone Lubricant 

is NSF Registered H1 No. 01519 














facilities. 





Nonchlorinated 

electric cleaner 

Nonflammable 

electronic cleaner 

K2 Electronic Cleaner is a nonchlorinated, 

plastic-safe cleaner 

that is engineered to rapidly clean 

and restore electronic components. 

K2 Electronic Cleaner is 

NSF Registered K2 No. 146516 














facilities. 



K2 NF Electronic Cleaner is 

a nonflammable, heavy-duty 

electronic cleaner that is engineered 

to rapidly clean and 

restore electronic components. 

K2 NF Electronic Cleaner is NSF 

Registered K2 No. 146517 and 

packaged with DETEX, metal 













facilities. 




Rescue kit 

The Miller QuickPick 

Rescue Kit delivers 

peace-of-mind during 

unexpected, peer-rescue 

situations involving 

those working at 

height. The rescuer 

can attach the system 

to the suspended 

worker while remaining 

securely anchored on 

the working surface. 

All rescue components 

are included in 

an easy-to-store kit 

with no required assembly. The kit is available in two configurations: 

the Premium Miller QuickPick Kit designed for 

workers whose job is not normally rescue, and the Standard 

Miller QuickPick Kit designed for those experienced 

in rescue situations. The kits are a professional solution 

that enhance worker safety and comply with corporate fall 

protection plans. 

Miller Fall Protection 

www.millerfallprotection.com 

Safety gate 

The GateKeeper Mezzanine 

Safety Gate is 

a reciprocating barrier 

that creates a controlled 

access area where workers 

can safely load and 

unload from the edge of 

a mezzanine, pick module, 

or other elevated 

platforms. The barrier 

designed with the Gate- 

Keeper is interconnected 

and cannot be open at 

the same time. When the 

outer gate opens to allow 

pallets to enter the mezzanine 

level, the inner gate automatically closes, keeping 

workers out. The exclusive link bar design ensures that 

both gates always work in unison, without relying on the 

chains or cables. Also featured with the GateKeeper is a 

Saf-T-Latch, preventing workers from raising the outer gate 

while inside the work zone. 



Vehicle restraint 

The RHR-4000 Dok- 

Lok Vehicle Restraint 

adds another layer of 

safety by securing overseas 

container chassis, 

which can have a plate 

of obstruction above 

the rear impact guard. 

The RHR-4000 offers a 

water- and dust-resistant 

IP66 rated motor and a 

longer lasting, corrosive-resistant 

finish that 

meets the ASTM B117 

testing standard. Like 

previous Dok-Loks, the RHR-4000 helps prevent all types 

of trailer separation accidents, including early departure 

and landing gear collapse, as well as trailer creep, popup, 

upending, and tip over. The Dok-Lok rotating hook 

restraints are designed for impact and to withstand the 

loading dock environment. 



Virtual main system 

Schneider Electric offers 

an arc flash mitigation solution 

to upgrade Unit Substation 

equipment with the addition 

of a virtual main system. 

The system reduces arc 

flash energy on low-voltage 

switchgear, including the 

main incoming section. The 

virtual main system features 

a switching device with fault 

interruption capability on the 

high-voltage side of the service 

transformer. The system 

provides maintenance mode 

for arc flash reduction, improving 

the overcurrent protection 

of unit substation. The virtual 

main system is equipped with 

a built-in fault recording and 

event reconstruction technology in the digital relay. 






Safety 

Fail-safe program 

Siemens introduced the SIMATIC STEP 7 Safety 

Advanced V11 option as a part of its Totally Integrated 

Automation (TIA) Portal, providing end users with all configuration 

and programming tools required for generating 

a fail-safe program. The TIA Portal integrates product and 

production engineering via one interface, linking all of Siemens 

automation software packages and platforms. The 

framework of the TIA Portal enables all Siemens Programmable 

Controllers, HMI operator panel, and drives to be 

configured in the same development environment. The 

new Safety Advanced feature allows for intuitive operation 

and quick entry into the generation of fail-safe programs. 

Siemens 


Braided hose 

The Series AH2 Braided Hose is an extension of the 

VicFlex Sprinkler Fitting System. The hose is 100% kink 

resistant, offering a tight bend radius at 2 in., as well as a 

new level of installation ease and advantage. The VicFlex 

hose also offers an improved hydraulic performance with 

a 50% lower friction loss over corrugated systems. The 

improved corrugation and braided technology reduce the 

effort needed to bend the hose, allowing for better shape 

retention. The Series AH2 Braided Hose is cULus Listed and 

FM Approved in combination with the Style AB1 Bracket. 

Victaulic 

www.victaulic.com 

Fire suppression 

system 

The Victaulic Vortex 

500 Fire Suppression 

System is designed 

specifically for information 

technology spaces 

such as data rooms and 

server spaces. This technology 

utilizes both water 

and nitrogen in a combined 

suspension to both 

cool the hazard area and 

remove oxygen that sustains 

the fire using high 

velocity and low pressure. The swirling distribution fills 

the hazard space at 40 mph and extinguishes the fire with 

little to no water. The Victaulic Vortex 500 system provides 

supreme protection and fire suppression with limited residual 

moisture, no toxic chemicals, and full design flexibility. 

Victaulic 

www.victaulic.com 

Now 

the vote 

is yours… 


Plant Engineering subscribers with 

a valid e-mail address will receive 

the 2012 Product of the Year ballot. 

Simply fill it out, click ‘Submit,’ 

and let your vote for this year’s best 

products be counted. Then, in the April 

2013 issue of Plant Engineering, meet 

the 2012 Product of the Year award 

winners honored at our 2013 Awards in 

Manufacturing Event in Chicago. 


Product Index 

Company Product Category Page 

24/7 Systems Inc. Tango Mobile Rounds Logging Productivity Training Software 53 

AeroGo Inc. LoadRunner Material Handling Systems 49 

aPriori Inc. aPriori 2011r2 Apps For Engineers 36 

B&B Electronics Mfg. 802.11 WiFi Access Point for Industrial M2M Applications Automation & Controls 30 

Baldor Electric Co. Dodge Type EXL Electric Motors & Drives 38 

Banner Engineering Corp. SureCross Q45 Wireless Photoelectric Sensor Automation & Controls 30 

Big Ass Fan Co. AirGo Misting System Environmental Health 42 

Big Ass Fan Co. BAFWorks Automation & Controls 30 

Big Ass Fan Co. Powerfoil X2.0 HVAC 44 

Cat Lift Trucks 2EP5000-2EP6500 Electric Pneumatic Tire Lift Trucks Material Handling Systems 49 

CBS ArcSafe RRS-3 AK-1/2-50 Safety 54 

CBS ArcSafe RRS-3 VR Safety 54 

CBS ArcSafe RRS-4 Safety 54 

CBS ArcSafe RSA-11A Safety 54 

CBS ArcSafe RSA-12A Safety 55 

CBS ArcSafe RSA-29 Safety 55 

Columbia Lighting e•poc LED Full Distribution Luminaire Lighting 45 

Columbia Lighting Serrano Architectural Luminaire Lighting 45 

Columbia Lighting Serrano LED Architecturally Styled Luminaire Lighting 45 

Columbus McKinnon Corp. Lodestar Electric Chain Hoist Material Handling Systems 49 

Detroit Radiant Products Co. MP Series ‘Modulating Plus’ Overhead Infrared Heaters HVAC 44 

Dual-Lite EV Series LED Lighting 45 

Eaton Corporation Arc-Resistant Front-Accessible Switchgear Power Transmission 51 

Eaton Corporation C441 Ethernet Series of Communications Cards Automation & Controls 30 

Eaton Corporation DC Disconnects Safety 55 

Eaton Corporation Drawout MCCB Pow-R-Line Panelboard and Switchboard Power Transmission 51 

Eaton Corporation Foreseer X-Class Software Energy Management 41 

Eaton Corporation H-Max Series Adjustable Frequency Drives Electric Motors & Drives 38 

Eaton Corporation Power Xpert 200E Gateway Energy Management 41 

Eaton Corporation Power Xpert Reporting v3.0 Energy Management 41 

Eaton Corporation Power Xpert Solar 1,500 kW Inverter Power Transmission 51 

Eaton Corporation POWEREDGE Mobile Application Apps For Engineers 36 

Eaton Corporation S811+/S801+ Soft Starters Electric Motors & Drives 38 

Eaton Corporation Series 6001 Energy Storage Grid-Connect Inverter Power Transmission 51 

Eaton Corporation SmartWire-DT System Automation & Controls 31 

Eaton Corporation W-VACiMB Medium-Voltage Vacuum Circuit Breaker Safety 55 

Eaton Corporation XV Series HMI-PLC Automation & Controls 31 

Electro Static Technology Inc. AEGIS Split uKIT Electric Motors & Drives 38 

Erich Industries Inc. Safety Sentry Warning Signal Alarm Safety 56 

Eriez SumpDoc Fluid Handling 43 

EXAIR Corporation Dual High Temperature Cabinet Cooler System Electrical Controls 40 

EXAIR Corporation Siphon Fed Atomizing Nozzles Fluid Handling 43 

EXAIR Corporation Super Air Nozzles Compressed Air 37 

EXAIR Corporation USB Data Logger for Digital Flowmeter Energy Management 41 

Exlar Tritex II DC Powered Actuators Electric Motors & Drives 39 

Exxon Mobil Corp. Mobil SHC Gear Oil Series Maintenance Tools & Equipment 47 

FastEST Inc. FasMate FN Series Fluid Handling 43 

Fluke Corp. Fluke 430 Series II Three-Phase Power Quality and Energy Analyzers Maintenance Tools & Equipment 47 

Fluke Corp. Fluke 805 Vibration Meter Maintenance Tools & Equipment 47 

Fluke Corp. Fluke Ti Series Thermal Imagers Maintenance Tools & Equipment 47 

FreeWave Technologies I/O Expansion Module Automation & Controls 31 

Frommelt Safety Guardian Defender Automated Barrier Door Safety 56 

Frommelt Safety Insulator Dock Seal Energy Management 42 

Gorbel Inc. Tether Track Swing Arm Fall Arrest System Safety 56 

GPAllied inspired Blended Learning Productivity Training Software 53 

Hubbell Building Automation Inc. CX Commercial Lighting Control Panels Automation & Controls 32 

Hubbell Building Automation Inc. LightHAWK Neutral Wall Switch Occupancy Sensors Automation & Controls 32 

Hubbell Industrial Lighting HBL LED Highbay Lighting 46 


Product Index 

Company Product Category Page 

Hubbell Outdoor Lighting Sedona LED Lighting 46 

Ingersoll-Rand plc Heat of Compression Dryers Compressed Air 37 

Ingersoll-Rand plc R-Series Rotary Screw Air Compressors Compressed Air 37 

Invensys Operations Management Eurotherm Nanodac Recorder/Controller Historian Automation & Controls 32 

Invensys Operations Management Intelligent Marshalling for Foxboro I/A Series DCS Automation & Controls 32 

Invensys Operations Management Wonderware InTouch 2012 Apps For Engineers 36 

iQuest iQagent Apps For Engineers 36 

Jungheinrich Warehouse Products ECR 327/336 Electric End-Rider Pallet Trucks Material Handling Systems 49 

Juno Lighting Group AccuLite Highbay and Lowbay LED Luminaires Lighting 46 

Kepware Technologies Inc. KEPServerEX 5.9 Automation & Controls 33 

Liftow Limited Cormack Propane Safety Valve Safety 56 

LPS Laboratories LPS DETEX Belt Dressing (2216) Safety 57 

LPS Laboratories LPS DETEX Clear Penetrating Grease (6716) Safety 57 

LPS Laboratories LPS DETEX Food Grade Chain Lubricant (6016) Safety 57 

LPS Laboratories LPS DETEX Food Grade Machine Oil (1316) Safety 57 

LPS Laboratories LPS DETEX Food Grade Silicone (1716) Safety 58 

LPS Laboratories LPS DETEX Heavy-Duty Silicone Lubricant (51516) Safety 58 

LPS Laboratories LPS DETEX K2 Electronic Cleaner (57116) Safety 58 

LPS Laboratories LPS DETEX K2 NF Electronic Cleaner (57016) Safety 58 

Miller Fall Protection Miller QuickPick Rescue Kit Safety 59 

Nexen Group Inc. Harmonic Gearhead Automation & Controls 33 

NK Technologies ATS Current Sensing Switch and Transducer Electrical Controls 40 

NovaTorque Gen2.0 PremiumPlus+, ECPM Motors Electric Motors & Drives 39 

Pro-face GP4000 Series Modular HMI Automation & Controls 33 

Prüftechnik Group ROTALIGN Ultra iS with sensALIGN Maintenance Tools & Equipment 48 

Prüftechnik Group VIBCONNECT RF Automation & Controls 34 

Ramsay Corp. Test Scramblizer Productivity Training Software 53 

RIDGID SeeSnake MAX rM200 Camera System Maintenance Tools & Equipment 48 

Rite Hite Holding Corp. GateKeeper Mezzanine Safety Gate Safety 59 

Rite Hite Holding Corp. Renegade Series HVLS Fans HVAC 44 

Rite Hite Holding Corp. RHR-4000 Dok-Lok Vehicle Restraint Safety 59 

Rockwell Automation Inc. Allen-Bradley CompactLogix 5370 PACs Automation & Controls 34 

Rockwell Automation Inc. Allen-Bradley Kinetix 350 Single-Axis EtherNet/IP Servo Drive Electric Motors & Drives 39 

Rockwell Automation Inc. FactoryTalk VantagePoint 4.0 Productivity Training Software 53 

Rockwell Automation Inc. PlantPAx Virtual Image Templates Automation & Controls 34 

Schneider Electric Aisle-way Beacon Maintenance Tools & Equipment 48 

Schneider Electric StruxureWare Power Monitoring 7.0 Software Automation & Controls 34 

Schneider Electric Unit Substation “Virtual” Main Circuit Breaker Solution Safety 59 

Siemens SIMATIC HMI Comfort Panels Automation & Controls 35 

Siemens SIMATIC S7-1215C Automation & Controls 35 

Siemens SIMATIC STEP 7 Safety Advanced V11 Safety 60 

Siemens SINAMICS DC Master Base Drive Electric Motors & Drives 39 

Siemens SINAMICS S120 Drive w/ Industrial Ethernet Electric Motors & Drives 40 

Siemens SINUMERIK OP 019 CNC Operator Panel Electric Motors & Drives 40 

SixAxis LLC Atlatl-Sales Resource Planning Software Automation & Controls 35 

Spirax-Sarco Inc. Steam DesignPro 6.1 HVAC 44 

Spirax-Sarco Inc. VLM10 Inline Vortex Mass Flowmeter Fluid Handling 43 

Sullair Corp. E900H Portable Air Compressor Compressed Air 37 

Sumitomo Machinery Corp. of America Cyclo Bevel Buddybox 4 (BBB4) Power Transmission 52 

Sumitomo Machinery Corp. of America Cyclo Bevel Buddybox 5 (BBB5) Power Transmission 52 

The Raymond Corp. Raymond 7000 Series Reach-Fork Trucks Material Handling Systems 50 

The Raymond Corp. Raymond 8000 Series Pallet Trucks Material Handling Systems 50 

Thomson Industries Inc. WhisperTrak Electric Linear Actuators Power Transmission 52 

Toyota Industrial Equipment Galvanized Chassis Material Handling Systems 50 

VaporLok Products VaporLokCapture Environmental Health 42 

Victaulic Series AH2 Braided Hose Safety 60 

Victaulic Victaulic Vortex 500 Fire Suppression System Safety 60 

VYCON Inc. VDC-XE with HC Option Energy Management 42 


SPECIAL ADVERTISING SECTION 


You’ve meet the finalists for Product of the Year. After you’ve 

completed the electronic ballot, you can learn more about the 

finalists and the products they offer. Our special Product of the 

Year advertising section provides a way to make plants 

run more efficiently, safely and productively. 

 

Companies interested in entering the 2013 Product of the Year competition may do so before the Sept. 2 7, 2013 

deadline. Details and entry forms will be available Apr. 15, 2013, at www.plantengineering.com/POY 


★ 

A VOTE FOR RAYMOND 

IS A VOTE FOR 

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Vote for the 7000 series Reach-Fork ® trucks and the 8000 series 

pallet trucks as your Plant Engineering Product of the Year, in the 

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View Live Plant Data on Your iPad®! 

What if you could use your iPhone® 

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uest,Inc. 

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Ingersoll Rand has unleashed two products, nominated for Product of the Year, 

that optimize the efficiency and productivity of your compressed air system: 

Long-Life, Contact-Cooled R-Series Rotary Compressors (55-160 kW) 

• Leak free, reliable components lower cost of ownership 

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• Flexible options such as fixed- and variable-speed motors, single- and 

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• Low pressure drop design conserves energy 

• Patented stainless steel heat exchangers provide optimal performance 

Ingersoll Rand Efficiency... 


ingersollrandproducts.com


Hubbell Building Automation

The new Fluke 805 Vibration Meter is more 

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•F o u r- l e ve l scale quickly assesses 

problem severity 

•U n i q u e sensor design ensures accurate 

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Forget the pens. Think METER: fluke.com/VibrationMeter 



AUTOMATIONSOLUTIONS 

Courtesy: AutomationDirect 

Remote monitoring technologies 

lower costs, improve operations 

The latest remote communication technologies allow experts to 

monitor and control multiple plants from any location. 

By Greg Philbrook 

AutomationDirect 

Remote monitoring isn’t new to the 

industrial automation world as over 

25 years ago the first remote monitoring 

systems were installed using 

dial-up phone connections. In the 1990s, 

these early systems advanced to hardwired 

Ethernet/Internet connections that offered 

greater speed and reliability. Today, many 

plants are benefiting from technologies in 

which wireless networks and devices are used 

for easier and more economical remote monitoring 

and control. 

The advent of cellular technology has significantly 

expanded the ability to monitor 

plant operations from just about anywhere, 

while lowering costs and simplifying implementation. 

4G technologies have made cellular 

connections much faster, often matching 

the speed of hardwired Ethernet/Internet 

connections. 

Benefits of remote monitoring 

Once only found in significant numbers in 

industrial applications that covered widely 

dispersed areas, remote monitoring is becoming 

a more integral part of daily operations 

in many manufacturing facilities, thanks to 

the lower costs and simpler implementation 

associated with the newest technologies. 

Some of the factors driving remote monitoring 

proliferation have to do with lower upfront 

investment costs needed for implementation; 


aUTOMaTIONSOLUTIONS 

Remote monitoring 

is becoming a more 

integral part of 

daily operations in 

many manufacturing 

facilities, thanks 

to the lower costs 

and simpler 

implementation 

associated with 

the newest 

technologies. 

others are the result of leaner operations and 

fewer operators on the plant floor. Not only 

does remote monitoring enable operators to 

monitor conditions from just about anywhere, 

it also facilitates more effective monitoring 

by fewer personnel, a real differentiator in 

today’s tough economic climate. 

The potential benefits of remote monitoring 

are significant: minimizing labor costs, filling 

the knowledge gap resulting from experienced 

operators retiring, prolonging equipment life, 

preventing unplanned downtime, and more. 

However, there’s no easy answer as to what 

type of remote monitoring is best. 

While remote monitoring can greatly contribute 

to cost savings and improved operations, 

there are considerations that must be 

addressed to ensure the security and practicality 

of implementing a remote monitoring 

system. Also required are definitions of what 

data can be accessed and by whom, and, most 

critically, what remote control options will 

be allowed. 

Wireless advantages and challenges 

Installing wireless networks for remote 

monitoring systems is becoming a common 

way to reduce costs associated with installing 

and maintaining a network. Wireless networks 

offer significantly more flexibility than wired 

remote monitoring networks that have a fixed 

topology. The ability to mix and match equipment 

from different suppliers is also much 

easier with wireless. 

Eliminating the need to purchase and install 

wires and cables is the most immediate cost 

savings associated with implementing a wireless 

network. Another area for savings is the 

Some advantages, disadvantages 

of wireless networks 

Advantages: 

n Flexibility for different hardware 

and software types 

n No cables or wiring 

n Faster and easier installation 

n Can provide greater visibility into 

operations. 

Challenges: 

n Not a closed system as with wired 

networks 

n Early security standards not robust 

n Implementation of new security 

technologies can be challenging. 

ability to add sensors much faster and for very 

little cost versus the high price of adding a 

hardwired device. 

Adding sensors improves visibility into a 

machine’s overall function, or to the overall 

performance of a batch or continuous process. 

The additional data gathered from new sensors 

enables operators to diagnose potential problems 

faster and with better accuracy, which 

leads to improved efficiency and reduced 

maintenance costs. 

While providing much lower installation 

costs, wireless networks aren’t a panacea for 

every situation or plant. The biggest concern 

with using wireless networks is security. Early 

wireless standards, such as wired equivalent 

privacy (WEP), were not as robust as they 

should have been, which has led to continuing 

concerns about data security over wireless 

networks. 

Although security measures are vastly better 

today, it is still important to remember that 

wireless networks can be more vulnerable 

than their wired counterparts. However, wireless 

networks have become far more secure 

through the use of encryption, and through 

standards such as the IEEE.802.11X-based 

Extensible Authentication Protocol, which 

requires clients to be identified in order to 

gain access to the network. 

But implementing and maintaining wireless 

network security requires certain IT 

knowledge, and smaller operations may not 

know how to implement these new security 

measures. Although wireless networks may 

pose a challenge for some users, wirelesses 

networking protocols and security features 

have advanced considerably, and wireless 

networks are definitely a viable option for 

reducing remote monitoring installation and 

maintenance costs. 

Remote data access 

Regardless of the type of remote monitoring 

system, great strides have been made in terms 

of how and where the data from these systems 

can be accessed. In the late 1990s, PC-based 

access became the norm, later followed by 

Web-based access. 

These developments not only lowered costs, 

but also improved efficiency and productivity 

because plant operators could more easily 

and frequently access data. In addition 

to easier data access, PC-based monitoring 

brought about significant improvements in 

alarming and alarm response times. Now, 

many plants are taking advantage of the 


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ability to use mobile devices such 

as Smartphones to reduce costs and 

gain greater visibility into plant 

operations. 

Whether as a result of the recession 

or experienced operators retiring, 

most manufacturing plants 

have fewer operators to monitor 

plant conditions. Process monitoring 

requires extensive oversight, 

yet plant managers can no longer 

afford to operate isolated diagnostics 

stations or assign certain 

operators to specific areas of the 

plant. 

In today’s plants, many operators 

must simultaneously monitor 

multiple machines or processes 

in various locations throughout 

a facility. Without remote monitoring, 

potential problems may not be 

detected, quality can suffer, equipment 

can be damaged, and unscheduled 

downtime can occur. 

More manufacturers are moving to 

consolidated monitoring models that 

Remote monitoring 

via Smartphones 

Web browser/VPN for remote monitoring: 

n May provide snapshot, not real-time data 

n May be read-only 

n Often not designed for small displays 

n Security challenges. 

Smartphone app for remote monitoring: 

n Very low cost 

n Wide range of functionality 

n Fast loading of app 

n High-speed access 

n Seamless upgrades from the supplier 

n Designed for small displays 

n Security challenges. 

cover multiple plants. With these models, 

highly experienced operators and 

engineers can access detailed, realtime 

information from each plant, as 

well as detailed historical information. 

Information from different plants can 

be compared and analyzed, often 

leading to early problem detection. 

Remote personnel can troubleshoot 

issues, change an operating 

parameter, and shut down a 

machine or process to avoid possible 

problems. They can also advise 

on-site engineers and operators as 

to how best remedy a problem or 

improve performance. 

This type of expertise combined 

with real-time visibility into daily 

operating conditions can extend 

the lifetime of machinery and 

process equipment. Maintenance 

schedules and historical data can 

more easily be used to determine 

maintenance and replacement 

intervals, all without having to 

be physically at the plant. 

Cellular technology use 

Smartphones have replaced individual 

devices that once seemed absolutely 

necessary. Watches, alarm clocks, cameras, 

maps, video recorders, calculators, 

Your operation is only 

Trust T&B Engineered 

components to keep your 

operation running. 

Wire & Cable Management • Cable Protection Systems

ecording devices, and much more now 

fit into a typical user’s pocket. It’s no 

wonder that the advances in cellular 

technology are being taken advantage 

of in manufacturing environments. 

Everyday more companies are using 

mobile devices such as Smartphones, 

tablets, and other handheld devices to 

cut costs, and to communicate information 

economically and quickly. While 

many manufacturers are enabling 

remote access via Smartphones and 

other handheld devices, implementation 

isn’t quite as simple as checking 

e-mail online. 

One of the main decisions to be made 

is how and when to implement browserand 

app-based remote monitoring. 

Web browsers: Pros and cons 

The logical progression for accessing 

data remotely via a Smartphone is to use 

a browser to access plant automation 

systems via a company’s virtual private 

network (VPN). Many companies today 

offer remote connectivity via a VPN, 

with users simply connecting to the 

company’s network and then interacting 

with the automation systems via a 

Web browser interface. This access is 

generally to a human machine interface 

(HMI) or a controller, although 

browser-based access can be used with 

any automation component equipped 

with Web-served capability. 

This type of access can be very good 

and relatively quick when the browser 

is running on a PC, but can raise issues 

with Smartphone browsers. In many 

cases, the Web server screens don’t 

scale well to the smaller displays found 

in handheld devices, and screens often 

take too long to load. 

Another consideration is that often 

remote browser-based access provides 

only a snapshot of the HMI screens, 

which can cause problems when monitoring 

large amounts of data in operating 

conditions that change frequently. 

Some Web servers and VPNs enable 

two-way access for remote control, 

but many just offer read-only access. 

INTERACT 

www.plantengineering.com/interact 

Q: Does your plant implement browseror 

app-based remote monitoring What 

applications do you use 

Therefore, care must be taken when 

selecting a supplier or implementing a 

VPN solution to make sure users can 

perform remote actions as necessary. 

While Web browser access is essentially 

free, the costs of designing, 

deploying, and maintaining the VPN and 

the Web servers can be considerable and 

must be factored in when determining 

overall ROI. 

Continued on pg. 86 

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Ingress Protection 

T&B Sealed Power Connectors 

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Ties with stainless steel locking 

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T&B Motor Lead Disconnects 

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You may not think of electrical components as a means to better productivity, but we have ways to help prevent 

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Power Connection & Control • Safety Technology • HVAC Building Solutions • Engineered Transmission Structures


Solar kits allow accurate monitoring and 

control of processes or equiment without a 

power infrastructure. Courtesy: B&B 

Electronics 

like local decision-making and controls, and 

redundant backhaul paths. 

Using sensors 

to enhance systems 

Recognize the limitations, then plan 

for redundancy. 

By Mike Fahrion 

B&B Electronics 

The network edge is continually expanding 

into new applications and new 

industries, and network-enabled sensors 

are leading the way. Metcalfe’s 

Law tells us that every time you add another 

device to a network, whatever that device’s 

function may be, you increase the value of 

the network. 

Sensors demonstrate that point every day. 

Whether they’re measuring deformation errors 

in a tire plant, geo-fencing an oil pipeline, or 

monitoring well water quality for the U.S. 

Geological Survey, sensors lower costs and 

enhance productivity. 

Each new application presents its own set of 

new problems. Sensors must function in a wide 

array of environments, and they must be able 

to report their data. This article will describe 

system design techniques that anticipate issues 

like brownouts and equipment failure, and 

prepare for them by employing solutions 

The myth of 100% uptime 

All data communications installations have 

vulnerabilities. Fiber optic cable, for example, 

the option with by far the greatest range and 

bandwidth, is used by the telecommunications 

companies to move data across entire 

continents. 

Uptime is excellent, but the system isn’t 

perfect. The cables are either run through sewers, 

where backhoes break them with annoying 

regularity, or they’re strung along telephone 

poles, where they’re knocked down by everything 

from windstorms to sleepy truck drivers. 

Indoor fiber optic connections have problems 

of their own. Transceivers and receivers eventually 

fail. Cables can be bent or broken by 

anything from careless forklift drivers to the 

cousins of the raccoons that get into power 

substations and shut down the grid. 

Copper cable adds additional weaknesses. 

Any strong magnetic field can induce current 

on a copper cable, which will lead to power 

surges that can burn out sensors, integrated 

circuits, and connectors. Industrial machinery 

isn’t the only thing that can generate those 

strong magnetic fields. For example, a 1989 

solar flare famously produced a magnetic 

storm that took out the power grid for all of 

Quebec. Lightning strikes will also produce 

damaging electrical events, as will the ground 

loops that occur when connected devices have 

different ground potentials. 

Wireless connections are subject to failure, 

too. Interference from other devices on 

the same frequencies can lead to data loss. 

And radio signals attenuate with the square 

of distance. Merely doubling the range would 

require a four-fold increase in power. 

No system is perfect. And the harder you try 

to achieve perfection, the faster your costs will 

rise. It’s cheaper and easier to eliminate the 

need for 100% uptime from the very beginning. 

Rugged devices and isolation 

While 100% uptime is a mirage, at least for 

a price that any reasonable person would be 

willing to pay, that doesn’t mean you shouldn’t 

try to do your best. Industry-hardened network 

devices that will stand up to off-the-desktop, 


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Monitoring remote assets 

via discrete analog and digital 

sensors and controlling 

remote control equipment 

from a central SCADA/PLC 

can both be accomplished 

with a single compact, rugged 

unit. Courtesy: B&B 

Electronics 

Each new application 

presents its own set 

of new problems. 

Sensors must function 

in a wide array of 

environments, and 

they must be able to 

report their data. 

real-world conditions can minimize many 

potential problems. 

Their copper connecting cables can be 

equipped with isolators. Unlike surge suppressors, 

which only try to limit spikes between 

the signal and ground line, isolators allow the 

lines to float while keeping the local side at the 

proper ground and signal level. USB connections, 

which are becoming ubiquitous because 

of their usefulness, also have an unfortunate 

proclivity for permitting ground loops. They 

should be isolated as a matter of course. 

Planning for downtime 

Occasional glitches and communications 

failures are a fact of life. After you’ve done 

your best to eliminate the potential problems 

caused by equipment failure, human error, solar 

flares, and pesky raccoons, it’s time to start 

planning for what will happen when communications 

fail anyway. 

You can solve many problems by placing 

enhanced intelligence and local decision making 

at the end point, rather than calling for 

unbroken connectivity with the central controller. 

Autonomy at the sensor’s end is a great way 

to get around connection glitches and variations 

in bandwidth. Monitoring can be done in 

a “store and forward” scheme where the local 

sensor has the ability to store data and send/ 

resend it as needed. That is becoming easier and 

easier to implement. Processors keep growing 

more powerful, yet their power requirements 

keep dropping. Sensors can now be equipped 

with powerful internal processors as well as significant 

quantities of internal memory. That’s 

a great substitute for perfect uptime. 

One good example would be the U.S. Geological 

Survey (USGS) mentioned earlier. The 

USGS monitors well and surface water conditions 

at sites all over the country and uses the 

data to make ongoing updates to its website. 

As you might expect, many of its sensors are 

deployed in very remote locations, and in places 

where there is no access to the power grid and 

no Internet infrastructure. Data communications 

are handled by low-power radio transmitters. 

Because the transmitters have low power 

but must broadcast across large distances and 

overcome interference, there will be ongoing 

fluctuations in bandwidth and link quality. 

Trying to achieve 100% uptime in such 

circumstances would be absurd. Instead, the 

sensors use localized intelligence to record and 

store data, and they send/resend until they are 

satisfied that the information has been passed 

along. 

Redundant backhaul 

Cable of one kind or another, with its built-in 

security, bandwidth, and reliability, normally 

forms the basic infrastructure of an industrial 

LAN. But what happens if you’d like to establish 

redundant backhaul and nudge your uptime 

rate that much closer to 100% Cable installations 

involve a lot of labor and materials; 

they aren’t cheap. If the main infrastructure 

is already wired, you might consider using 

wireless as the backup. (It’s what the telecoms 

did while they were rebuilding their fiber 

optic networks in the aftermath of Hurricane 

Katrina.) 

There are a number of ways to go about it, 

depending on what you need to accomplish. 

With advances in multiple-in, multiple out 

(MIMO) technology and associated developments, 

Wi-Fi now has very serviceable range 

and bandwidth capabilities. It uses licensefree 

frequencies, which presents a financial 

advantage, and it is inherently interoperable 

with off-the-shelf wireless network adapters, 

laptops, tablets, and even Smartphones. For 

many applications Wi-Fi would be a very costeffective 

and uncomplicated way to establish 

redundant backhaul. 

Wi-Fi does have range limitations. You’ll 

need another wireless option if you need to 

establish M2M communication over long 

distances and the connections must be under 

your own control. Companies like Conel, in the 

Czech Republic, specialize in enabling users 

to maintain data communications over the cellular 

telephone network. The packet transfer 

system lets users employ any station in the 

network as an end station or as a retranslation 

station, allowing for networks with complex 

topology and vast size. Data transfer can be 

encrypted, and the system will support your 

choice of protocols. 

The technology is mature enough that 3G 

often serves as the backhaul for telecommunications 

and broadband services in countries 

like Belize, where a fiber build-out in difficult 

terrain like jungles and mountains would be 

far too expensive. 

The goal of 100% connectivity remains 

elusive. But industrial-grade installations, 

alternative power, and redundant backhaul 

combined with smart sensors can get you 

very, very close. P E 

Mike Fahrion, the director of product management 

at B&B Electronics, is an expert in 

data communications with 20 years of design 

and application experience. 


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MAINTENANCESOLUTIONS 

Courtesy: Hoffman 

Smaller, more flexible enclosures 

still need to be rugged 

Cabinets allow for safe and accessible storage, but can generate dangerous heat. 

By Brian Mordick 

Hoffman 

Technology advancements are resulting 

in electronics playing a greater 

role in the daily activities of business 

and manufacturing plants than 

ever before. A direct effect of the additional 

network and electronics is the growing 

demand for connectivity and network 

equipment to be relocated from centralized 

data centers—where conditions can be carefully 

monitored and controlled—to localized 

network and wireless applications, placing 

them at the point of control or activity. 

This increases the potential for exposure to 

the often harsh manufacturing conditions 

or environmental elements. To accommodate 

these changing needs, enclosure solutions 

have had to adapt to provide more 

flexible and controlled access, enhanced 

protection, durability, and performance versatility. 

As component size decreases, PCB density 

increases, allowing more electronics 

and networking equipment to fit into smaller 

spaces. Now, control, networking, and 

security monitoring equipment that once 

filled full-size electronic enclosures easily 

fit into a smaller enclosure that can be 

affixed to a wall or mounted directly 

onto a machine—freeing up valuable 

floor space. 

Wall-mount cabinets allow manufacturers to 

safely store electronics where they are needed 

most, without exposing them to industrial conditions. 

However, these small, highly dense 

electronics generate a significant amount of 

heat. Therefore, the ideal wall-mount enclosure 

will offer thermal management capabilities, 

adapt to changing networking requirements, 

and accommodate a wide variety of 

applications. 


mAINTENANCESOLUTIONS 

Ideal wall-mount enclosures will offer thermal management capabilities and 

accommodate a wide variety of applications. Courtesy: Hoffman 

Along with selecting enclosures 

to complement equipment size and 

location, cabinet specifiers must also 

consider the application challenges 

and environmental conditions that can 

compromise an enclosure’s integrity. 

Exposure to extreme temperatures, 

corrosive agents, or impact can damage 

enclosures. 

Wall-mount enclosures 

Within industrial facilities, floor 

space is valuable, and many companies 

measure productivity and efficiency by 

dividing the amount of floor space by 

dollars generated. Consequently, installing 

a full-size electronics enclosure can 

take up valuable floor space that could 

otherwise be designated for equipment 

or machines and becomes detrimental to 

plant productivity. Wall-mount cabinets 

house and protect a variety of electronics 

and networking devices, conveniently 

mounting on walls or machines. 

To accommodate the demand for networking 

flexibility, wall-mount enclosures 

can be used to extend the data center 

via intermediate distribution frame 

(IDF), which further supports remote 

access points (AP) for wireless applications. 

An IDF is a free-standing or 

wall-mounted rack used to manage and 

interconnect cables between end-user 

devices and a main distribution frame 

(MDF). 

AP applications utilize dedicated 

hardware devices that act as a central 

transmitter and receiver for wireless signals. 

By supporting both IDF and AP 

networking applications, wall-mount 

enclosures aid in extending networks to 

remote locations to handle a broad scope 

of activities, such as industrial controls, 

access control, HVAC, monitoring, security/cameras, 

communications, building 

automation systems, and more. 

When selecting the ideal wall-mount 

solution, users should take multiple 

factors into consideration, such as 

space limitations, enclosure size, cable 

management, and any thermal issues. 

Wall-mount cabinets should provide 

easy access to equipment. For instance, 

single-door cabinets offer a cost-effective 

solution for protecting, securing, 

and cooling a host of equipment, while 

double-hinged door cabinets facilitate 

easy front and rear equipment access, 

enhancing access to cabling and reducing 

time to install and connect system 

components. 

Wall-mount cabinets are available in 

standard sizes and with custom options 

to support all types of networking and 

industrial electronics—both 19-in. rackmounted 

and traditional back panel 

mounted. In addition to the enclosure 

size, users must also consider how far 

the cabinet will extend from the wall or 

machine on which they intend to mount 

the unit. To avoid collisions in public 

aisle ways, cabinets should typically 

extend less than 12 in., but requirements 

can vary depending on application. 

Cable management 

Cable management is a crucial aspect 

in cabinet selection. Proper, efficient 

cable management provides organization 

and support. For applications requiring 



a simple solution, cable knock-outs 

allow cables to easily enter and exit 

the cabinet. Alternatively, in demanding 

applications where the enclosure’s 

rating integrity must be maintained, 

gland plates, which are removable 

sections of the enclosure, offer an 

outlet for cable egress. Gland plates 

not only provide cable management 

without compromising the enclosure, 

but they also accommodate evolving 

network needs by allowing cables to be 

frequently changed or added. 

Along with providing environment 

protection and management for cables 

entering or exiting a cabinet, internal 

cable organization minimizes stress 

points while still supporting frequent 

cable moves, additions, and changes 

(MACs). To accommodate these needs, 

wall-mount enclosures contain vertical 

and horizontal cable managers. This 

allows the cabinet to support all categories 

of networking cables, providing 

flexible cable management capabilities. 

Thermal management is another 

critical factor when selecting enclosure 

solutions. Electronics and networking 

equipment generate heat, requiring thermal 

management to protect components 

from overheating. Ranging from simple, 

passive cooling to complex solutions, 

thermal management capacities should 

correspond to the amount of heat generated 

by equipment being housed. The 

most advanced wall-mount cabinets 

combine protection, support, and access 

with integrated thermal management for 

a comprehensive enclosure solution. 

Enclosure materials 

Protecting electronics and equipment 

from harsh industrial conditions 

requires enclosure and cabinet solutions 

that isolate and secure devices and connections 

from the surrounding environment. 

Non-metallic enclosure solutions 

provide rugged durability and enhanced 

longevity for applications repeatedly 

exposed to caustic chemicals or temperature 

changes, offering an alternative 

to traditional steel enclosures. 

Two prevalent non-metallic options 

include fiberglass and polyester. Also, 

non-metallic cabinets allow Wi-Fi signals 

to freely exit, protecting the equipment 

without impeding signals. 

INTERACT 


Q: How does your plant maintain 

continual network function, improve 

overall efficiency, and increase 

productivity 

Fiberglass 

Fiberglass is a common non-metallic 

material used in networking applications, 

due to its capacity to resist 

chemical exposure and extreme temperature 

changes—providing a costeffective 

alternative to stainless steel 

for corrosive environments. Composed 

of a high-performing, engineered 

composite resin, fiberglass 

enclosures are typically formed in one 

of two ways: compression molding or 

spray-up process. 

Compression molding incorporates 

precision-designed molds to deliver 

superior part uniformity and material 

consistency, and utilizes a material 

known as SMC, which is a long-glassfiber 

pigmented polyester resin. These 

long fibers provide superior strength 

and, when formulated with UV inhibitors 

and aluminum trihydrate, they resist 

material degradation. 

Further, this combination enables the 

enclosure to achieve the UL 94 5V flammability 

rating, which classifies the rate 

of burning, time to extinguish, ability 

to resist dripping, and whether or not 

the drips are burning. This rating is the 

highest performance requirement for a 

UL 508 enclosure. 

The second method of fiberglass 

enclosure forming, the hand lay-up or 

spray-up process, also delivers similar 

advantages. The molding used in this 

process also ensures part uniformity and 

material consistency, as well as achieves 

the UL 94 5V flame-resistance rating. 

Plus, its heavy, unfilled pigmented outer 

gel coat layer provides rugged protection 

against environmental contaminates 

or exposure. 

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Cabinet design must address the application challenges and 

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Polyester 

The use of hybrid polycarbonate/polyester blends for nonmetallic 

enclosures is a relatively new development. Providing 

an alternative to traditional non-metallic enclosures, 

its thermoplastic material delivers high impact resistance, 

enhanced electrical properties, and superior chemical and 

moisture resistance. 

Unlike fiberglass enclosures, which eventually break 

under extreme pressure, polyester is engineered to absorb 

tremendous amounts of pressure without shattering. With 

its inherent durability, polyester is also less susceptible to 

scratches and abrasions. Featuring flame-retardant properties, 

fannenberg_Plant_1_4.indd 3 

3/1/12 8:04 PM 


electronic newsletters 

deliver news and information on the latest trends in manufacturing 

in every corner of the plant floor. Plant engineers and managers 

refer to these sources of information for the up-to-the-minute 

news and trends that impact their business. 

PlantMail: published Weekly 

HotWire: published Monthly 

HotWire on MES: published Monthly 

HotWire on Automation: published Monthly 

Maintenance Connection: published Monthly 

Product Showcase: published Monthly 

Sustainable Manufacturing: published Monthly 

It’s time to get your plant 

ahead of the curve. 

Subscribe today. 

www.plantengineering.com/newsletters

polyester performs well in extreme temperatures and 

will not ignite when in contact with fire. Further, polyester’s 

corrosion and chemical resistance enables these 

units to withstand the highest range of solvents, alkalis, and 

acids without failure. 

Additionally, since polyester produces virtually no dust, it 

can be easily drilled and punched for holes and cutouts—even 

in the field—without contamination. By lacking glass particles, 

polyester is not susceptible to fiber bloom, minimizing 

the risk of product contamination and skin irritation, as well 

as reducing wear on tools. Plus, constructed of recyclable, 

thermal molded components, polyester is an eco-friendly 

enclosure material. 

Conclusion 

By understanding the available enclosure options, their 

advantages and performance capabilities, cabinet specifiers 

can select the ideal solution to perform in virtually 

any application, from limited spacing to damaging 

environments. Implementing the proper enclosure is 

instrumental in maintaining continual network function, 

which, in turn, improves overall efficiency 

and productivity. P E 

Brian Mordick is senior product manager for the Hoffman 

Plant Engineering brand of Pentair 8-10:Layout Technical 1 Products. 7/13/10 5:18 PM Page 1 

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Continued from pg. 75 

Using apps for monitoring 

and control 

A different approach for using Smartphones 

and handheld devices to monitor 

and control operations remotely 

involves the use of apps specifically 

designed for these devices. Extremely 

economical, with some costing as little 

as five dollars, Smartphone apps can be 

an optimal method for accessing data. 

Some of these apps may offer the ability 

to view and control operations as if the 

user were in the control room in front of 

the HMI screen. However, as with the 

VPN/Web browser combination, care 

must be taken. 

To create fully 

functioning remote 

monitoring apps for 

Smartphones, developers 

must increase 

hardware, software, 

and protocol performance 

levels to 

reduce the latencies 

that can occur over 

remote connections. 

If not, users can 

become frustrated 

by slow or poor performance. 

To optimize 

performance, 

developers must also 

reduce the amount of 

data transfer from the 

automation components, 

typically HMIs and controllers. 

When done correctly, using an app 

to access data via a Smartphone can 

be very cost-effective and reliable. Joel 

Froese, owner/operator of the Red Bank 

Hydro Plant in Columbia, S.C., uses 

his Smartphone for remote access as 

depicted in Image 2. “I can access data 

anytime and anywhere to ensure I have 

optimal operating conditions. I can start 

or stop the plant just as if I were standing 

in front of the HMI. The screens 

are scaled correctly, safety features are 

included, and I can quickly access the 

data I need.” 

Not only is app access often superior 

in terms of performance, but it’s 

also easier to load. Browser access via 

a Smartphone requires a user to load 

up the browser, then enter the address 

Everyday, more companies 

are using mobile devices 

to cut costs and to communicate 

information 

economically and quickly. 

While many manufacturers 

are enabling remote 

access via Smartphones 

and other handheld devices, 

implementation isn’t 

quite as simple as checking 

e-mail online. 

and wait for a screen to load. By contrast, 

app access is much quicker and 

requires fewer steps. Finally, app access 

typically requires much less IT support 

than VPN/Web browser remote access. 

Security issues 

Just as with implementing a wireless 

remote monitoring system, new security 

measures must be implemented when 

accessing sensitive data via a Smartphone 

or handheld device. Regardless of 

whether a Web browser or Smartphone 

app is used, remote access must be protected 

from unauthorized personnel, and 

access levels must be controlled. 

Methods and technologies exist to 

make remote wireless 

connections more 

secure. These security 

measures are similar 

to those used for other 

wireless communications: 

encryption, 

password authorization, 

and device identification. 

The required security 

settings and procedures 

can be too 

time-consuming or 

difficult for some 

plant managers and 

control engineers. 

To alleviate this 

situation, neophyte 

users should select 

a company that provides a high level 

of service, and has a deep understanding 

of both the security requirements 

and the technologies needed 

to make access via handheld devices 

feasible and smart. 

Not every manufacturing plant will 

employ the same remote monitoring 

systems, as each system has its own 

pros and cons, and as each plant has 

different needs. But regardless of the 

type of access used, remote monitoring 

will become more the norm as technologies 

advance and as the need to 

accomplish more with fewer resources 

continues. P E 

Greg Philbrook is HMI/Communications 

product manager for Automation- 

Direct. 



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MECHANICALSOLUTIONS 

Three oil contamination examples: The 

left-most sample contains a new premium 

grade industrial mineral oil — no contamination. 

The center sample contains the 

same oil grade after five years of intermediate 

service in an oil film bearing with 

minimal external contamination. The oil 

is notably darker and has visible metallic 

particles suspended. The last sample contains 

the same oil grade with water contamination. 

Notice the cloudy appearance. 

Courtesy: Baldor 

Particulates, liquids, 

oxidation contribute 

to oil contamination 

Oil discoloration should be addressed with high 

importance for optimal operation performance. 

By Andrew Myers 

Baldor 

Maintaining proper oil quality is essential 

for satisfactory operation and 

longevity of oil film bearings. Oil 

discoloration is a sign of potentially 

harmful contamination or degradation. There 

are three main causes of oil discoloration in 

oil film bearings: particulate contamination 

(external and internal), liquid contamination, 

and oxidation. Each cause has some unique 

characteristics, but discoloration is often a 

combination of the three. 

Particulates, external and internal 

External particulate contamination refers to 

particles that are ingested from the surrounding 

environment. In an oil film bearing there 

is a radial clearance between the bearing liner 

and shaft to allow for shaft movement as the 

oil film develops. There are also axial shaft 

movements due to thrust loads and shaft expansions/contractions. 

These shaft movements, inherently, make 

completely sealing the bearing around the shaft 

a challenge. Without special sealing, small 

particulates in countless forms (lime and coal 

dust, sand/silicon, soot, metal chips, etc.) can 

work their way into the bearing and discolor/ 

darken the oil. 

During maintenance and installation, 

when the bearing housing is open, the 

bearing is exposed to large scale particulate 

contamination. For this reason it is 

recommended to thoroughly clean and 

flush the bearing with clean oil after it has 

been opened. 

In addition to particulate contamination 

coming from external sources, there are internal 

sources of particulate contamination that 

come from inside the bearing. To begin with, 

there will naturally be some wear particles 

generated each time a hydrodynamic bearing 

is started or stopped. These wear particles 

are created when the shaft is rotating below 

the minimum speed required to develop a full 

oil film. Without a full oil film, the shaft rubs 

against the white metal (babbitt) in the bearing 

liner. This is commonly referred to as boundary 

lubrication. 

The babbitt is a soft metal alloy designed to 

protect the shaft and will generate wear particles 

primarily in the form of tin, lead, and 

antimony. The babbitt also protects the shaft 

by embedding contaminates, but this has its 

limitations. If particulates are too large, they 

will not fully embed in the babbitt and will 

begin to score the shaft. 

A large concentration of small particles can 

also build up in the babbitt and lead to shaft 

scoring. Shaft wear particles (iron, chromium, 

etc.) will then further contaminate the oil and 

propagate the wear. Internal wear particles, just 


mechanicalSOLUTIONS 

like external particulates, will 

generally cause the oil to darken. 

Shaft surface finish plays a 

critical role in controlling the 

amount of wear developed during 

starts and stops. Minor scoring, 

pitting, or sharp edges on 

the shaft should be smoothed out 

as much as possible. For most 

applications, shafts should have 

a surface finish of 32 micro in. 

or better. 

Iron wear particles may also 

be generated in the contact areas 

between the bearing housing and 

liner. A minor amount of constructive 

wear in these areas can 

be expected when a new housing 

or liner is installed and the new surfaces 

mate or “seat” together. 

However, if the liner is not clamped 

securely in the housing, or if there is 

vibration in the system, the contact 

surfaces can begin to abnormally wear 

or fret and produce iron particulates. A 

visual inspection of these contact areas 

Oil film bearings can be found in just about every type 

of industrial environment and are therefore exposed to 

countless forms of contaminates. Courtesy: Baldor 

for wear should be performed during routine 

maintenance to rule out this source 

of contaminates. 

Oil rings and seals are other sources 

of internally generated wear. Oil rings, 

usually made of bronze, rest freely on 

the shaft and can rub against the oil ring 

grooves and produce copper and tin 

particles. However, during 

operation, oil rings are continuously 

coated in oil and should 

not cause significant wear. Shaft 

seals come in many different 

configurations and materials 

including aluminum and nitrile 

elastomer. A well-designed shaft 

seal, if properly installed and 

maintained, should not generate 

significant amounts of wear 

particles. 

One last source of internal particulate 

contamination is actually 

from new oil. Studies have been 

conducted to show that new oil 

can contain a large quantity and 

wide variety of contaminates 

ranging from metallic wear particles to 

large organic debris. It is a good practice 

to filter the oil using a 10 µm, or finer, filter 

before ever pouring it into the bearing. 

If a circulating oil system is to be used, 

then the standard practice is to filter the 

new oil with a finer filter than the filter 

used in the circulating oil system. 

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Liquids 

Liquid contaminates are simply contaminates 

in the liquid state. The most 

common liquid contaminate in oil film 

bearings is water. Water or water vapor, 

just like external particulates, may enter 

the bearing through the clearances around 

the shaft seals and migrate into the oil. 

The presence of water in oil will make 

it appear cloudy or milky in appearance. 

Water has many harmful effects in 

bearings including rust/corrosion, accelerated 

oil oxidation, depletion of oil 

additives, and dilution of oil viscosity 

properties. Too much water can degrade 

the oil properties to a point to which the 

oil film will not develop at all. For these 

reasons, it is recommended to keep the 

water content less than 500 ppm (1,000 

ppm maximum). 

Other forms of liquid contaminates 

can be cleaners, lubricants, assembly 

chemicals, assembly greases, process 

chemicals, and detergents. These can 

cause a wide range of oil discolorations 

and changes in chemical composition. 

Care should be taken to prevent these 

contaminates from entering the bearing, 

and extra precautions should be in 

place to ensure that oils are not mixed 

during installation or during routine oil 

checks/refills. 

The same oil used for lubrication 

(during operation) should also be used 

for cleaning and assembling. Simply 

knowing the color of the correct oil is 

an important step in preventing and 

identifying this type of contamination. 

Oxidation 

Oil oxidation is one last source of oil 

discoloration. Oil oxidation is a process 

of chemical degradation that naturally 

occurs in oil over time when it is exposed 

to air. Some of its by-products are sludge, 

varnish, and acid, which cause the oil to 

thicken and darken. Higher temperatures 

(above 160 F for mineral oils) accelerate 

oxidation, as well as other contaminates 

such as water, iron, and copper. Synthetic 

oils are available which have better 

oxidation resistance than conventional 

INTERACT 


Q: How often are you checking on the 

oil quality for your systems How often 

SHOULD you check it 

oils and can be considered to extend oil 

change intervals. 

Oil analysis 

There are many types of oil analysis 

tests available today. The most informative 

tests for oil film bearings show oil 

viscosity, water content, total acid number 

(oxidation indicator), and parts per 

million for each contaminate type. Due 

to reasons described previously, some 


mechanicalSOLUTIONS 

small (less than 10µm) particulate is to 

be expected under normal operation; 

therefore, keeping a trend of particle 

count is more helpful than a single particle 

count for assessing bearing performance. 

A spike in particle count during 

steady operation (few starts and stops) 

is indicative of external contamination 

or abnormal wear. Particles of 10µm or 

larger are on the same magnitude as the 

oil film thickness, and should be kept to 

a minimum in order to prevent abnormal 

wear. 

A very practical tool for analyzing 

oil samples in the field is an oil patch 

test kit. An oil patch test can be used to 

get quick test results of the contamination 

level in the oil without waiting for 

results from a laboratory. 

In addition to oil sampling, monitoring 

the bearing operating temperature 

can detect changes in oil conditions. 

High levels of contamination and degradation 

result in increased friction and 

oil film breakdown, which will lead to 

a rise in operating temperature. 

Oil type 

The recommended oil for oil film 

bearings is a premium grade, industrial 

mineral oil or turbine oil, with rust and 

oxidation inhibitors and anti-foaming 

agents. Extreme pressure (EP) additives 

are not recommended. Oil viscosity 

is determined individually for 

each application and is based on bearing 

clearances, loads, temperatures, 

and speeds. For units operating in hot 

or cold climates, synthetic oils can be 

considered which will not thicken as 

much at low temperatures and which 

will have better oxidation resistance at 

high temperatures. 

Conclusion 

Oil discoloration in oil film bearings is 

a visible indication of oil contamination 

or degradation. Contamination comes in 

two main forms: particulates and liquids. 

Particulates can either be ingested from 

the environment or come from inside the 

bearing. Liquid contaminates can come 

from the environment, but they can also 

be inadvertently added to the bearing in 

the form of incompatible cleaners and 

lubricants. 

Oil degradation will naturally occur 

over time through oxidation. Regardless 

of the source, significant oil discoloration 

should be addressed with high 

importance. Slight discoloration does 

not necessarily indicate a problem. The 

lubricant supplier ultimately determines 

the acceptability. 

Oil is the lifeblood for oil film bearings, 

and maintaining proper quality 

through regular oil replacement and 

analysis will greatly increase the longevity 

and reliability of the bearings. P E 


Andrew Myers is a Baldor applications 

engineer for Dodge Sleeve 

Bearings. 

92 • November 2012 plant engineering

PRODUCTMART 


electronic newsletters 

deliver news and information on the 

latest trends in manufacturing in 

every corner of the plant floor. Plant 

engineers and managers refer to 

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• HotWire: published Monthly 

• Maintenance Connection: 

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baldor.com 

Baldor Electric Co. designs, manufacturers, and markets 

a broad line of industrial energy-efficient electric motors, 

mechanical power transmission products, and more. 

Baldor Electric Co. 

donaldson.com 

Compressed air purifications solutions, compressed air 

filters, dryers and process water chillers. 

Donaldson Company Inc. 

exair.com 

Exair’s product line includes Vortex Tubes and products 

utilizing Vortex Tubes, Air Amplifiers, Air Knives, air-operated 

vacuums and ionizing products for static elimination. 

Exair Corp. 

flexicon.com 

Flexicon Corp. designs and manufactures bulk handling 

equipment and custom-engineered and integrated plantwide 

systems. 

Flexicon Corp. 

fluke.com 

Fluke Corp. is the world leader in the manufacture, distribution, 

and service of electronic test tools and software. 

Fluke Corp. 

ge-energy.com 

GE Energy is one of the world’s leading suppliers of power 

generation and energy delivery technologies. GE Energy 

provides integrated products, services, and solutions in all 

areas of the energy industry. 

General Electric Co. 

November 2012 

For more information on how to advertise in Plant EnginEEring’s 

Internet Connection, call Jim Langhenry at 630-571-4070 x2203 

gorbel.com 

Gorbel provides a wide variety of overhead handling solutions 

that handle loads from 50 lbs up to 40 tons. 

Gorbel Inc. 

grainger.com 

Grainger is a leading distributor of industrial supplies, 

MRO equipment, tools, and materials. MRO, manufacturing, 

supply chain, tools, and more. 

Grainger Inc. 

hamiltoncaster.com 

Casters at Hamilton Caster. Your source for heavy duty 

industrial casters, stainless steel casters, caster wheels 

and polyurethane wheels. 

Hamilton Caster 

hyster.com 

Hyster offers a comprehensive range of warehousing 

equipment, industrial lift trucks, container handlers and 

reach stackers as well as quality material handling parts. 

Hyster Co. 

lubriplate.com 

Lubriplate manufactures more than 200 high quality lubricants, 

including high performance synthetic lubricants and 

NSF-H1 lubricants for food processing and beverage. 

Lubriplate Lubricants Co. 

mhia.org 

MHIA is the leading non-profit trade association representing 

the U.S. material handling and logistics industry. 

Material Handling Industry of America 

omega.com 

Omega offers more than 100,000 state-of-the-art products 

for measurement and control of temperature, humidity, 

pressure, strain, force, flow, level, pH, and more. 

Omega Engineering Inc. 

pentair.com 

Pentair Ltd. delivers industry-leading products, services 

and solutions for needs in water and other fluids, thermal 

management and equipment protection. 

Pentair Ltd. 

ridgid.com 

Every tool that bears the RIDGID brand is engineered to 

the same high standards of quality, strength, and endurance 

as was the first heavy-duty pipe wrench. 

Ridge Tool Co. 

rigalite.com 

Rig-A-Lite leads the industry in innovative solutions and 

ruggedly designed products for marine lighting, industrial 

lighting, specialty lighting, petroleum lighting and food processing 

lighting. 

Rig-A-Lite Industrial Lighting 

rosler.us 

The Rosler group is the leading supplier of surface finishing 

equipment and consumables. Products include mass 

finishing and show blast equipment, wastewater treatment 

systems, and compounds for mass finishing. 

Rosler Metal Finishing USA 

selinc.com 

SEL serves electric power utilities and industrial sites 

worldwide through the design, manufacture, and support 

of digital protective relays and automation products, plus 

services for power system protection, control, monitoring, 

integration, and automation. 

Schweitzer Engineering Labs 

seweurodrive.com 

One of the largest global suppliers of drive technology, 

SEW-EURODRIVE specializes in gear reducers, motors 

and electronic motor controls. 

SEW-EURODRIVE USA 

usa.siemens.com/drives 

One of the world’s leading motor manufacturers, Siemens 

offers NEMA, ANEMA, IEC, ac motors, dc motors, and 

Motors for motion control and machine tools. 

Siemens Motors & Drives 

spiraxsarco.com 

Spirax Sarco applies world class knowledge, service and 

products to the efficient pressure and flow control of steam 

and other industrial fluids. 

Spirax Sarco Inc. 

stanleyproto.com 

Pros who work the demanding jobs demand Stanley 

Proto. Our industrial hand tools are built to be precise, 

durable and make work easier. 

Stanley Proto 

sullair.com 

AirMetrix is a total system management program designed 

to maximize the productivity of your compressed air system. 

AirTility delivers air as needed with no capital expenditures 

and no maintenance worries. 

Sullair Corp. 

tnb.com 

Thomas & Betts supplies over 70% of the items used in a 

typical electrical application and provides market-leading 

commercial heating and ventilation products. 

Thomas & Betts Corp. 

yaskawa.com 

Yaskawa is the world’s largest manufacturer of ac inverter 

drives, servo and motion control, and robotics automation 

systems. 

Yaskawa America Inc. 

Place next to your computer or go online to plantengineering.com for hot links to these companies. 

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CONTACTS Advertiser Contacts for plant engineers 

Request more information about products and advertisers in this issue by using the http://plantengineering.hotims.com 

link and reader service number located near each. If you’re reading the digital edition, the link will be live. When you contact a 

company directly, please let them know you read about them in Plant Engineering. 

Page RSC Send 

Advertiser Number Number Info 

Aggreko LLC 16 11 

866-215-7966 www.aggreko.com 

Allied Electronics 11 7 

800-433-5700 www.alliedelec.com 

ALL-TEST Pro, LLC 86 40 

860-399-4222 www.alltestpro.com/c/246 

Atlas Copco Compressors 22 17 

866-688-9611 www.atlascopco.com/drivenbyefficiency 

AutomationDirect C-2 1 

800-633-0405 www.automationdirect.com 

Baldor Electric Company C-4 47 

800-828-4920 www.baldor.com 

Detroit Radiant Products Company 70 29 

800-222-1100 www.reverberray.com 

Donaldson Co., Inc 2, 82 3, 35 

800-365-1331 www.donaldson.com 

Electro Static Technology, Inc 20 15 

866-738-1857 www.est-aegis.com 

Exair Corp 7 5 

800-903-9247 www.exair.com 

Flexicon Corp 8 6 

888-353-9426 www.flexicon.com 

Fluke Corp 4, 69 4, 28 

888-443-5853 www.fluke.com 

GE Energy 13 9 

203-373-2211 www.PeopleBehindThePromise.com/Vishal 

Gorbel, Inc 85 39 

585-924-6262 www.gorbel.com 

Grainger 77 32 

847-535-1000 www.grainger.com 

Hamilton Caster & MFG. Co. 92 45 

888-699-7164 www.HamiltonCaster.com 

Hankison 26 20 

724-745-1555 www.hankisonintl.com 

Hubbell Building Automation, Inc. 68 27 

888-698-3242 www.hubbell-automation.com 

Hyster 17, 27 12, 22 

800-HYSTER1 

www.hyster.com 

Ingersoll-Rand 67 26 

704-655-4000 www.ingersollrandproducts.com 

iQuest, Inc. 66 25 

813-909-1108 www.iQuestcorp.com 

Lubriplate Lubricants Co 80 34 

800-733-4755 www.lubriplate.com 

Advertiser 

Page RSC Send 

Number Number Info 

Master Bond, Inc 83 36 

201-343-8983 www.masterbond.com 

Material Handling Industry of America 87 41 

800-345-1815 www.mhia.org 

NuStar, Inc 12 8 

800-800-9274 www.powerpusher.com 

Omega Engineering, Inc 1 2 

888-556-6342 www.omega.com 

Pentair 25 19 

763-545-1730 www.PENTAIR.COM 

Pfannenberg USA 84 37 

716-685-6866 www.PfAdvantage.com 


Electronic Newsletters 84 

630-571-4070 www.plantengineering.com/newsletters 

Ramsay Corporation 85 38 

412-257-0734 www.ramsaycorp.com 

Raymond Corporation 64, 65 24 

800-235-7200 www.raymondcorp.com 

RIDGID 79 33 

800-769-7743 www.RIDGID.COM/PRESSING 

RIG-A-LITE 90 43 

713-943-0340 www.rigalite.com 

Rosler Metal Finishing USA 24 18 

269-441-3000 www.rosler.us 

Schweitzer Engineering Labs 91 44 

509-336-7946 www.selinc.com 

SEW-Eurodrive, Inc. 73 30 

www.seweurodrive.com 

Siemens Industry, Inc. 15 10 

800-241-4453 www.usa.siemens.com/ids-pe 

Spirax Sarco Inc 18, 19 13, 14 

800-883-4411 www.spiraxsarco.com/us 

Stanley Proto Industrial Tools 28 23 

800-800-8665 www.PROTOINDUSTRIAL.COM/PE 

Sullair Industrial Products 88 42 

219-879-5451 www.sullair.com 

Thomas & Betts Corporation 21, 74, 75 16, 31 

901-252-8000 www.tnb.com 

Vaisala, Inc. 26 21 

888-824-7252 www.vaisala.com/compressedair 

Yaskawa America, Inc C-3 46 

800-927-5292 www.yaskawa.com 

Need More Info FAX this page to: 630-214-4504 

or mail to PLANT ENGINEERING magazine, 1111 West 22nd Street, Suite 250, Oakbrook, IL 60523 

Name 

Title 

Company 

Address 

City State Zip 

Telephone Fax e-mail 

PLANT ENGINEERING does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the Advertiser contacts regardless of whether such errors result from negligence, accident, or any other cause whatsoever. 


INCONCLUSION 

Veterans can deliver skills to manufacturing 

Bob Vavra 

Content Manager 

Manufacturing leaders 

need to deliver the 

same level of service 

to our returning 

veterans that they 

have delivered to us 

during their time in 

the military. We would 

have this obligation 

even if there were not 

a skills gap. 

Last month’s launch of the Get Skills 

to Work program by the Manufacturing 

Institute and four major American 

manufacturers is to date the highest 

profile attempt by American manufacturing 

to bridge its ever-widening skills gap. 

Its stated goal is to link the hundreds of 

thousands of existing and projected 

American manufacturing jobs to the 

tide of military personnel returning 

from wars in Asia or from the end of their 

tours of duty. 

The link between veterans and manufacturing 

is the key to the program, 

and so the first four companies to 

sign up—Alcoa, Boeing, GE and 

Lockheed Martin—fully 

understand the relationship 

between a strong 

military and a strong manufacturing 

environment. They also see 

the strong connection between the 

two, especially at this pivotal time in 

manufacturing. All have a long tradition in 

American manufacturing; all of them also are 

major defense contractors or suppliers. 

There is an unquestioned need for skilled 

manufacturing workers, and enlisting military 

personnel is both a strong political and strategic 

move. Reaching out to reemploy veterans 

in the private sector after their service to 

their country was completed has long been a 

patriotic concept. More than at any time since 

World War II, Americans value the service of 

our military personnel, and this program is 

yet another attempt to recognize and honor 

that service. 

American military personnel are trained 

on some of the world’s most sophisticated 

equipment. They understand discipline, 

commitment to hard work and an ability 

to apply critical thinking to solve problems. 

This skill set is exactly what many 

manufacturing employers want and need as 

they address a technological evolution in 

manufacturing. Plant managers need 

this kind of skill set to be able to remain 

competitive in a global manufacturing environment. 

“Veterans offer the technical, leadership and 

critical thinking skills that advanced manufacturing 

demands,” said Paula Davis, president 

of the Alcoa Foundation, in a press release 

announcing the formation of the coalition. 

“Forming the Get Skills to Work coalition and 

coordinating with nonprofits to train, recruit 

and develop veterans is an exciting model that 

has the potential to change lives and produce 

a significant competitive advantage for U.S. 

manufacturers.” 

The timing of this announcement comes 

as wars are winding down in Afghanistan 

and Iraq and military personnel will 

be returning to civilian life. Get Skills to 

Work estimates that one million veterans 

will leave the Armed Forces 

over the next four years, 

while 600,000 high-tech manufacturing 

jobs remain 

unfilled. 

The return to civilian 

life from the military often is 

not easy. No one associated with 

the program underestimates that 

reality. We also can see the value of 

worker in our manufacturing ranks. For those 

who may struggle with what to do on their 

return from military service, Get Skills To 

Work offers a tangible direction and a clear 

path to the future. 

Manufacturing needs this influx of skilled 

talent. Manufacturing leaders need to deliver 

the same level of service to our returning 

veterans that they have delivered to us 

during their time in the military. We would 

have this obligation even if there were not 

a skills gap. The fact that one exists is all 

the more reason to get moving on this initiative 

today. 

The roster of manufacturers involved in 

Get Skills to Work current stands at four. 

I expect that roster to grow rapidly. But 

even without the formal involvement in this 

program, manufacturers around the country 

can and should tap into this resource without 

delay. 

Our soldiers are coming home, and a 

warm greeting and a parade is one way to 

welcome them home. But after the parade is 

over, let’s make sure we have a job training 

program and a job in manufacturing waiting 

for them. It’s good for manufacturing, 

it’s good for our veterans and that has to be 

good for America. P E 


WHAT YOU 

ALWAYS WANTED 

Our customers tell us that quality means no product hardware failures. Now, that’s a gift that keeps 

on giving. 

When you take Yaskawa drives out of the box, you can count on them to work. In fact, Yaskawa 

products have a meantime-between-failure rate (MTBF) of up to 28 years. That means your engineers 

can spec Yaskawa and never have to worry. Just program, plug and play. 

Get what you want, every time. Call Yaskawa. 

YASKAWA AMERICA, INC. 

DRIVES & MOTION DIVISION 

1-800-YASKAWA YASKAWA.COM 

Follow us: 

For more info: 

http://Ez.com/yai397 


©2012 Yaskawa America Inc.

DC On Demand 

While other manufacturers have chosen to leave the 

DC motor market, ABB and Baldor continue to invest in 

product development and U.S. manufacturing in order to 

offer the widest variety of permanent magnet and wound 

field industrial DC motors in the world. 

DC motors continue to provide the right solutions to 

many application requirements. We now can supply IEC 

or NEMA frame motors, stock motors from 1/50 to 500 

Hp or custom-designed motors to 3000 Hp to meet your 

specific application. If you need a DC motor anywhere 

in the world, call Baldor! 

baldor.com 479-646-4711 

• The Most DC Choices 

• Unmatched Quality 

• Superior Reliability 

• Quickest Delivery Available 

• American Made Since 1920 

©2012 Baldor Electric Company 

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