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LA u t u m n 2 0 0 3

Society for theENVIRONMENT

Biogas Energy

Nursery Robotics

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BRANCH MEETINGS

DIARY of EVENTSNOVEMBER 2003

Monday 3 November 19.30 h – Wrekin BranchState of the Countryside 2020Speaker: Mike Grace, Regional Director, Countryside AgencyVenue: Harper Adams University College

Monday 10 November 19.30 h – South East Midlands BranchQuality Standards in Potato Industry and Potential Implications for

Agricultural Engineering DevelopmentsSpeaker: Professor E Allen, Cambridge UniversityVenue: Conference Room, SRI,Wrest Park, Silsoe

Monday 10 November 19.30 h – West Midlands BranchTractor Manufacturing in Coventry 1946-2003 Speaker: Roger ReedVenue:AGCO, Banner Lane, CoventryFor more information email: [email protected]

Thursday 13 November 19.30 h – Herts & Essex BranchModern Combine Harvester TechnologySpeaker from CNH UK LtdVenue: CNH Basildon

Friday 14 November 19.30 h – East Anglian BranchBranch Annual DinnerVenue: Brome Grange

Wednesday 19 November 14.30 h – Northern Ireland BranchVisit to two working Carier Slurry Separators on farms in the Omagh

area followed by ‘Ulster Fry’ (approx. 17.00 h) and discussion of the the-ory and practice of separation.

Arranged through Trevor Linton, NI Carier Agent

Wednesday 19 November 19.30 h – Scottish BranchElectronics and Communications in Rural IndustriesSpeaker: Derek Smith, Forestry Commission – Radio and Electronics

BranchVenue: Lomond Hills Hotel, Freuchie, Fife

Thursday 20 November 19.30 h – Southern BranchRecent Developments in Oil Technology and the Outlook for the

FutureSpeaker: Colin Middleton, General Manager, Sales & Marketing, Morris

LubricantsVenue: Sparsholt College,Winchester, Hampshire

Tuesday 25 November – Western BranchWelding – demonstration of the latest welding technologies, tech-

niques and approachesVenue: Royal Agricultural College, CirencesterThere will be two sessions - one in the afternoon and then repeated in

the evening.Pre-booking required - £2.50 members, £5.00 non-members. Please con-

tact: Nick Paul, Branch SecretaryE mail: [email protected] or telephone: 01225 782347

DECEMBER 2003

Monday 8 December 19.30 h - South East Midlands BranchProviding the Tools for a Future Farming IndustrySpeaker: Caroline Drummond, LEAFVenue: Bar Function Rm, Cranfield University Silsoe

Tuesday 9 December 19.30 h – Scottish BranchRecent Developments in Grass Machinery for the FarmSpeaker: Jim CampbellVenue: SAC,Auchencruive by Ayr

Tuesday 9 December 19.30 h – West Midlands BranchCastrol/BP – Environmental Issues/Technical UpdateSpeaker: Russell CherieVenue: Friends Meeting House, Stratford upon AvonFor more information email: [email protected]

Thursday 11 December 19.30 h – Wrekin BranchYoung Engineer’s ChallengeOrganised by Kevin Scrivens and Denis Cartmel,Wrekin Branch

RepresentativesVenue: Harper Adams University College

JANUARY 2004

Monday 12 January 19.30 h – Wrekin BranchLand Rover Special VehiclesSpeaker: Bob Honnor, Commercial & Utility Business Manager, Land RoverVenue: Harper Adams University College

Monday 12 January 19.30h – South East Midlands BranchPrecision Livestock HusbandrySpeaker: Professor Christopher Wathes, Silsoe Research InstituteVenue: Conference Room, SRI,Wrest Park, Silsoe

Thursday 15 January 19.30 h – Herts & Essex BranchInspirations in Engineering Speaker: Eric May, CountytracVenue:Writtle College

January 14 or 15 - Northern Ireland BranchVisit to Mothers Pride BakerySpeaker: Lynne GowdyVenue: Mothers Pride Bakery,Apollo Road, BelfastDate and time to be confirmed.

JET INTERLINGUALJET Interlingual offers a specialist translating and inter-preting service in the Agricultural and Horticulturalindustries to cater for the needs of British exportersand importers.JET Interlingual can handle any language for technical,commercial and legal translations.

Key clients include the AEA and MLC.

I have used JET Interlingual to support a consultancy con-tract and was impressed by both their ability to translate thetechnical content and the excellent service provided.

Dr Dan Mitchell, President

For further information and our rates contact:

Jane Thomas(Associate Member of the Institute of Linguists)Tel and Fax: 01323 760326E-mail: [email protected]

Feature Articles2 SUSTAINABLE TECHNOLOGY

Anaerobic digestion within the UKDuncan Child

8 HORTICULTURAL ENGINEERINGRoundstone Nursery

John A C Weir11 PROFESSION

Society for the Environment (Soc Env)

Membership Matters centrefold15 Day in the life of... John E Moffitt

News and Comment7 News scan

17 Publication – Risk and Engineering20 Company and product information

Product Lifecyle Management

Front cover: Extended range of combine harvesters ( Courtesy: New Holland UK)

The views and opinions expressed in individual contributions are not those necessarily of IAgrE or the Editor.Landwards is compiled from information received by IAgrE but no responsibility can be accepted by the governingCouncil, the Publishers or the Editor in respect of any errors or omissions. The Editor reserves the right to edit anymaterial sent to the journal.Material from this publication may be quoted or reported on condition that full credit is given to Landwards and to theauthor, and that the date of publication and volume number are stated. In the interest of factual reporting, reference totrade names and proprietary products may be inevitable. No endorsement of the named products or manufacturers isintended and no adverse criticism is implied of similar products which are not mentioned.

© The Institution of Agricultural Engineers (IAgrE)ISSN 1363-8300

The Professional Journalfor Engineers, Scientists,

and Technologists in

Agriculture, Horticulture,Forestry, Environment

and Amenity

EditorEur Ing Prof Brian D Witney

PhD CEng FIMechE HonFIAgrE MemASAE FFCS

LAND TECHNOLOGY LTD33 South Barnton Ave,Edinburgh, EH4 6ANTel/Fax: 0131 336 3129E-mail: [email protected]: http://www.landtec.co.uk

AdvertisingAll enquiries to IAgrETel: 01525 861096Fax: 01525 861660

Origination: David King

Printing: Barr Printers Ltd

Publisher Landwards is published bimonthly by:IAgrE,West End Road, Silsoe,Bedford, MK45 4DUTel: 01525 861096Fax: 01525 861660E-mail: [email protected]: http://www.iagre.org

PresidentDr Dan Mitchell

CEng FIAgrE FRAgS

Chief Executive & SecretaryChristopher R WhetnallIEng FIAgrE MemASAE

LCONTENTS

ANDWARDSVolume 58 No 5, 2003

SummaryAnaerobic Digestion (AD) hasrecently been undergoing astate of revival within theEuropean Union (EU), mostnotably in Germany, wheremore than 50 AD plants, eachtreating at least 2500 tonnesper year of biowaste, are nowinstalled. It has also beenreceiving increasing interestwithin the UK, though the actualdevelopment and installation ofAD systems between the twocountries is very different.

Although AD in the UK iswell established within thewastewater treatment industry,it has a very chequered pastwithin other UK industrialsectors, most notably theagricultural sector where AD isstill perceived as beingunreliable, time consuming anduneconomic.

New technology andmethods have increased thereliability of AD systems andthere is a growing interest inthe technology especially withinthe food supply chain where theeffects of the EU LandfillDirective are beginning to befelt.

This article gives a briefoverview of AD within the EUand then examines thelegislation and drivers that willimpact on the development ofAD within the UK. It alsoexamines the resource that isaccessible and the different ADsystems and emergingtechnologies which are nowavailable for AD, to beconsidered as a viable optionwithin an integrated resource(waste) management supplychain.

Anaerobic digestionwithin the EuropeanUnionInterestingly, the development ofthe AD market within the EUhas somewhat mirrored thedevelopment of the EU windenergy industry. For example,Germany which does not havethe highest wind regime in theEU but does have the highestinstalled wind power capacity(Fig. 1), [European Wind EnergyAssociation].

This rapid growth in recentyears has been assisted bygovernment subsidies, as part ofits strategy to bring downgreenhouse gas emissions.Thisproactive stance from theGerman government is also truefor their support for thedevelopment of the AD marketwithin their country.This isillustrated in Fig. 2 which shows

LANDWARDS AUTUMN 20032

SUSTAINABLE TECHNOLOGY

WITHIN THE UKANAEROBIC DIGESTION

Duncan Child

This paper was presented at the

IAgrE Annual Conference entitled

‘Energy and the Land-based

Industries’ and held at Silsoe Research

Institute on 13 May 2003. Dr Duncan

Child is a Director of an independent

consultancy that provides feasibility

studies, services and solutions for

sustainable technologies with the

renewable energy, waste management

and manufacturing industries. Prior to

this Dr Child was a Senior Research

Fellow at De Monfort University,

Leicester. Sustainable Technologies

Solutions Ltd. Tel: +44 (0)1509

267817 E-mail:

[email protected]

Website:

www.sustainabletechnology.co.uk

BIO NOTE

Centralised anaerobic digestion

system at Holsworthy Biogas

plant in Devon (Photo:

Holsworthy Biogas)

3

the number of commercial ADplants, per EU country, that areprocessing more than 2500tonnes/year of biowaste and/ororganic industrial waste [IEABioenergy Task 37].

Within Germany, aRenewable Energy Law nowprovides a minimum price forelectricity generated from ADsystems as detailed in Table 1.

Of significance is that theseprices are fixed for a period of20 years.There are also grantsavailable of up to 30% ininterest reduced loans [Köttner,2003].These fiscal measureshave led to the rapiddevelopment of the AD marketin Germany, where there arenow more than 1200 farmbased AD systems.

The EU AD market is

predicted to reach 38.4 TWheby 2010, though a recentestimate suggests that it willonly reach 21.8 TWhe [Frost &Sullivan, 2003].This is partly dueto reduced or lack ofgovernment support for suchsystems. In contrast to theGerman fiscal support for ADsystems, the Danish governmenthas recently voted to removestate support in the form ofcapital grants for AD systems.Though a premium price isbeing paid for the electricity –0.6 DKK/kWh (£0.056/kWh),the Danish government want toreduce quite considerably thispremium.This has therefore hadthe effect of putting on hold anynew AD developments[Köttner, 2003].

Anaerobic digestion inthe UKThough AD in the UK is wellestablished within thewastewater treatment industry,it has a very chequered pastwithin other UK industrialsectors, most notably theagricultural sector where AD isstill perceived as beingunreliable, time consuming anduneconomic. New technologyand methods have increasedthe reliability of AD systemsand there is a growing interestin the technology especiallywithin the food supply chainwhere the effects of the EULandfill Directive are beginningto be felt [TV Energy, 2002].However, against this upsurgein interest,AD does notappear to receive the samelevel of support within UKgovernment circles as in otherEU countries.This is evident bythe distinct lack of discussionon AD within the recentlypublished UK Energy WhitePaper [DTI, 2003].Interestingly the referencecount for renewable energy

technologies within the paperis: wind 56; hydrogen 48;biomass 31; solar 21; tidal 17;wave 15;AD 1 and biogas 0.The one reference to ADrefers to the review into thedelivery of Waste Strategy2000:“…ensure that there arefinancial incentives to developnew waste technologies such aspyrolysis, gasification andanaerobic digestion.”

Likewise recent wastestrategy reviews do not seemto be too positive about thefuture for AD within the UKeither.The recently publishedCabinet Office Strategy Unit

report ‘Waste not,Want not’reviews the implementation ofWaste Strategy 2000 forEngland and Wales [StrategyUnit, UK Government CabinetOffice, 2002], regarding AD,merely states “Whilst trialed,not yet commercially proven inthe UK on municipal solid waste(MSW).” There is no mention ofeither agricultural waste or foodwaste which is of concern asthere is enormous potential forthe development of these twosectors, as evidenced by UKcompanies working within thesesectors.As evidenced in otherEU countries, the involvementof a proactive government andsupportive energy rates greatlyassists in the development ofthe AD market.

DriversA range of EU and UKlegislation provides the maindrivers for the UK AD market:

EU Landfill DirectiveBy 2020 the quantity ofbiodegradable municipal waste,being sent to landfill, must bereduced to 35% of the amountproduced in 1995.AD is seen asvital for achieving this target[Köttner, 2003].

EU Animal By-productsRegulationThe recent EU Animal By-products Regulation providesthe legal framework for thecollection, transportation,storage, handling, processing anddisposal of animal by-productsacross all sectors of the animalby-products supply chain[Department for theEnvironment, Food and RuralAffairs (DEFRA)].The method

Fig. 1 EU installed wind power 2002

Fig. 2 EU commercial anaerobic digestion plants processing > 2500tonnes/year of biowaste

Table 1 Electricity prices from anaerobic digestion systems inGermany



4

of treatment depends onwhether the material is classifiedas animal by-product or cateringwaste. For material classified asan animal by-product theoptions available are detailed inTable 2.

EU Biowaste DirectiveBy 2009 all member statesshould have separate collectionschemes for biodegradablewaste (biowaste), such askitchen waste [Green Party].

Renewables ObligationThe Renewables Obligationrequires that power supplier’ssource a defined amount of theelectricity that they supply totheir customers from renewableenergy sources.The requiredtargets are 3% by 2003 and 10%by 2010, subject to the costsbeing acceptable to theconsumer.

Climate Change LevyThe Climate Change Levy is atax on the use of energy inindustry, commerce and thepublic sector and forms anintegral part of theGovernment’s Climate ChangeProgramme.The attraction isthat electricity generated fromnew renewable energy isexempt from the levy.

ResourceAD has a very chequered pastwithin the UK, most notablywithin the agricultural sectorwhere AD has a history of beingunreliable, time consuming anduneconomic. Despite theseconcerns the potential for farmbased AD is significant, especiallyin the dairy and pig sectors asillustrated in Fig. 3 [C-TechInnovation Ltd, 2002].

This indicates that theavailable biogas energy that canbe derived from a farming unitusing AD, typically exceeds, by

some measure, the energyrequirement of that unit, asdemonstrated in equationformat below Fig. 3.

The resource potential forAD systems, within the UK, isdetailed in Table 3 [BritishBiogen, 1999].This suggests thatif all the available agriculturaland food derived wasteresource was utilised, thenabout 400 MWe and 600 MWecould be generated.Theseparated digestate is likely toconsist of 29 Mt/year of fibrousmatter and 58 Mt/year of liquidfertiliser.

SystemsThere are two main types of ADsystem that are being used forthe treatment of food waste andagricultural and horticulturalwaste, namely batch andcontinuous flow.

Batch digestionBatch digestion is synonymouswith the AD sytems that havebeen used for centuries with theFar East, notably China andIndia. It is simply a sealedcontainer in which the organicwaste is placed. Biologicaldecomposition occurs (with orwithout heating) and biogas isproduced. In effect it is the sameprocess as within a landfill site.

There has recently been anupsurge of interest within batchdigestion for the treatment ofagricultural and food processingwaste as it is more tolerant offeedstocks with a higher solidscontent.A recent example ofthis type of system within theUK is at Arrowe Park,Wirralwhere AMEC have developed abatch digester for food wasteand green MSW (Fig. 4).

The AD system has twonovel features in that it isgenerating electricity and heatusing a micro gas turbine and isalso integrated with agreenhouse, where the carbondioxide from the gas turbineexhaust is fed for plant uptake.The modular approach to thebatch process allows formaximum biogas extractionfrom each batch before it isremoved and replenished.Careful control of the cycling ofthe biogas production allows forcontinuous biogas production.

Another UK companypromoting a batch AD system isSustainable Waste Systems (Fig.5).This system is able to acceptboth solid and liquid waste byoperating a two phase system.The first phase is digestion ofsolid waste (e.g. agriculturalmanure, separated MSW, foodprocessing waste) within a

Table 2.Animal By-product treatment options

Fig. 3 Energy ratios for agricultural anaerobic digestion systems

5

sealed vessel.The second phaseis digestion of liquid waste (e.g.farm slurry, beverage processingwaste) within a second vessel.Liquor from the solid phase isdrained into the second vesselwhich can also accept otherliquid wastes.The liquid waste iscirculated through the contentsof the solid phase during thedigestion period [SustainableWaste Systems].

Continuous digestionA continuous AD process isanalogous to a cow eating grass.A cow regularly eats grass andafter a period of time producesbiogas from both ends of itsbody and defecates the fibrousnon-digestible matter. Likewise acontinuous AD process isregularly fed organic materialwhich is converted into biogasand the residual fibrous matteris removed for further

treatment.As a continuous ADis regularly diluted with freshmaterial the biogas productionrate is less than for a batchdigester.

An example of a small-scalecontinuous AD system is shownin Fig. 6.The 120 m3 AD, alongwith a 25 kW wind turbine and

a 50 kg/h gasifier, formed ahybrid renewable energy systemdeveloped at De MontfortUniversity as part of an ‘EUJoule’ project.The ADprocessed 10 tonnes/day ofprimarily pig slurry with amixture of vegetable wastes(typically brassicas, seedpotatoes and sugar beet).Thebiogas was stored in a 50 m3

biogas storage bag where it wasthen fed to a Capstone 30 kWmicro gas turbine.

An example of a large-scalecontinuous centralised ADsystem is shown in the titlephotograph. It is located atHolsworthy, Devon and is half

owned between HolsworthyBiogas (centralised ADoperator) and Farmatic(German AD developer).Thecentralised AD, built with theassistance of EuropeanObjective 5(b) Funding, treatscattle slurry and foodprocessing waste within a 30

mile radius.The centralised AD is

designed to treat 146,000tonnes of animal and foodprocessing waste and produceenough biogas to operate two1.2 MW gas engines.The surplusheat from the centralised AD isdesigned to be fed into a districtheating system which isintended to heat a local healthcentre, hospital and school.

Integrated digestionLeicester City Council haverecently awarded a 25 year£300M integrated wastemanagement contract to Biffa tosort household waste from

117,000 Leicester homes[BIFFA].The sorted organicwaste fraction will be fed to acontinuous AD system, whichwill provide 1.5 MWe.

The system is linked to alocal sewage works, which willtake the liquor from the ADsystem.The fibrous matter will

Table 3. Resource potential for anaerobic digestion systems in the UK

Fig. 4 AMEC Batch Digestion System (Photo:AMEC WasteResearch Station,Wirral)

Fig. 5 Portagester System (Photo: Sustainable Waste Systems)



6

be stored for 14 days beforebeing spread on agricultural landas a compost and soil improver.Though not directly processingagricultural and food waste, itdoes illustrate that forwardthinking is taking place withinUK organisations in how tomaximise the opportunities forelectrical and thermal energygeneration from multipleresource streams.

Emerging technologyThere is increasing interest inthe AD market and there are

several emerging technologiesthat are presently looking toexploit the opportunitiesavailable.

Micro gas turbinesA recent introduction into thesmall scale (<100 kW) energygeneration market is the microgas turbine [Bowman PowerLtd].Though they are typicallymore expensive then standardinternal combustion enginesystems, they have lowerrunning costs due to lowermaintenance costs.This is

primarily due to only having onemoving part – the rotor whichcontains both the turbine andgenerator (Fig. 7).This allows forsmoother operation and, due toit being a continuouscombustion process, it providesa more constant power output.They also have lower vibrationand emissions and are generallymore compact.There areseveral of these operating onbiogas within the EU (e.g.AMECWaste Research Station,Wirral)and it is anticipated that theywill become the primary powergeneration source foragricultural and food waste ADsystems.

Fuel cellsFuel cells through electrolysisrecombine hydrogen and oxygeninto water and in doing soproduce electricity.The interestin AD by fuel cell manufacturersis that hydrogen can be obtainedfrom the methane within thebiogas (Fig. 8).The technologicalchallenge is that extremely purehydrogen (i.e. no sulphur) isrequired.The main advantage offuel cells is that they have very

low emissions, long life cycles,low maintenance and highconversion efficiencies of about45%.

TransportAn application for biogas whichis being explored is the use ofbiogas as a fuel fortransportation. Eight Europeancities collaborated on an EUfunded project towards thebroad popularisation of energyefficient, environmentallyfriendly vehicles [Environmentand Health ProtectionAdministration, Stockholm]. Foruse as a fuel, the biogas needs tobe purified to a methanecontent of 97%.At this purity, 1m3 of biogas has the energyequivalent of about 1 litre ofunleaded petrol. In Stockholmthe cost of 1 m3 of biogas wasabout £0.06 less than the costof 1 litre of petrol.The AD plantthat is generating the biogas is asewage treatment works and itis being increased in size from250,000 m3 to 4.5 million m3.When completed it will provideenough biogas to power about3000 cars (there are already 500biogas powered cars inStockholm).The cost ofconverting a car from petrol tobiogas is between £1000 and£3000.

The FutureFor AD and other emergingenergy generating technologiesto become accepted within theUK, key stakeholders within theenergy and waste managementsupply chains need to beeducated as to the positiveattributes that thesetechnologies bring to theenvironmental debate. For ADwithin the agricultural andhorticultural sectors, the keystakeholders include farmers,growers, pack houses,processing companies, retailoutlets, planners, financialinstitutions, local councils andregional government.

A step change in thinkingabout AD is required if it is toovercome the problems

Fig 6. Continuous anaerobic digestion system

Fig. 7 Micro gas turbine (Photo: Bowman Power Systems)

7

associated with lack of centralsupport and the historical legacyof AD as being unreliable andtime consuming.To enable thisto occur,AD needs to be viewedas an integral function within theresource management of thewhole supply chain, rather than

just another waste managementtechnique that is included as anafterthought.There are alsoranges of different businessmodels available which do notnecessarily put all the financialand operational burden ontothe resource (waste) supplier.

AD systems are now beingdesigned and installed within theUK that are not only integratingAD with agricultural andhorticultural practices, but alsowith emerging energy generatingtechnologies [SustainableTechnology Solutions]. Byutilising the energy content ofthe residues in this way, thesesystems reduce the use of fossilfuels, methane emissions andlandfill disposal.

ReferencesBIFFA. www.biffa.co.uk

Bowman Power Ltd.

www.bowmanpower.com

British Biogen (1999).Anaerobic

Digestion of farm and food

processing residues. Good

Practice Guidelines

C-Tech Innovation Ltd (2002).

Agricultural waste mass balance:

opportunities for recycling and

producing energy from waste

technologies.

DEFRA. www.defra.gov.uk

DTI (2003). Our energy future –

creating a low carbon economy.

Energy White Paper, Department

of Trade and Industry

Environment and Health

Protection Administration.

Stockholm. www.zeus-europe.org

European Wind Energy

Association. www.ewea.org

Frost and Sullivan (2003).

European Biogas Power Plant

Markets B162-01, Research

Overview. www.frost.com

Green Party.

www.greenparty.org.uk

IEA Bioenergy.Task 37.

www.novaenergie.ch

Köttner M (2003). Biogas in

Agriculture and Industry

Potentials, Present use and

Perspectives. www.crest.org

Strategy Unit, UK Government

Cabinet Office (2002).Waste

not,Want not:A strategy for

tackling the waste problem in

England.

Sustainable Technology

Solutions. Hybrid Renewable

Energy System.

www.sustainabletechnology.co.uk

Sustainable Waste Systems.

www.safe-waste.com

TV Energy (2002). European

Bioenergy Networks, UK

Country Report.

Fig. 8 Typical biogas powered fuel cell

DagenhamNTI opensforbusinessMalcolm Carr-West, who for thelast ten years had led theAgricultural Engineeringdepartment at Writtle College ison the move. He is to take onthe role of co-ordinating a NewTechnology Institute (NTI), theDagenham NTI, which hasopened at the Centre forEngineering and ManufacturingExcellence (CEME) Campus, inEast London.

Led by LoughboroughUniversity, the Dagenham NTIwill work within the CEMEpartnership to enhance theengineering, business and

entrepreneurial skills beingtaught there, which have beenidentified as crucial to thesuccessful regeneration of thispart of the Thames Gatewayarea.

As well as offering courses inadvanced engineering at CEME,the Dagenham NTI will play avital backroom role, developingleading edge e-learningtechnologies, supporting studentswishing to progress to higher

education, and working with localindustry, from Ford down to thesmallest companies, to buildmanufacturing and businesscapability in the area.

Malcolm brings a wealth ofexperience in education andengineering to the post, and isrelishing the challenge that liesahead.

“This is the probably themost exciting development inengineering education in theThames area for a generation”,says Malcolm. “The work thatthe Dagenham NTI willcontribute to can make a realdifference in establishing Londonas a world city for advancedtechnologies, enhancing itspresent status as a centre for thefinance and service sectors.”

Chris Backhouse,Loughborough University’s Deanof Engineering says:“TheDagenham NTI is going to help

break down the divide betweenthe vocational and the academicin the education and skillsdebate, a distinction which CEMEconsiders to be mostly artificialand outdated.”

Described by London’smayor Ken Livingstone as “a vitallandmark in securing a successfuland sustainable economicenvironment in the Dagenhamregion”, CEME’s first students areenrolled, and taking the firststeps in realising the vision of itspublic-private partnership toregenerate the Thames Gatewayarea.

Contact: Richard Newbold,Loughborough UniversityBusiness Partnerships. Tel:01509-228692 Email:[email protected]

CONTACT


HORTICULTURAL ENGINEERING

ROUNDSTONE

Fred Milbourn (third left)

with some of the visit

group from the

Horticultural

Engineering Specialist

Group and the South

Eastern Branch, in the

Newlands loading bay,

against a background of

‘Danish trolleys’, filled

with end-packs of

bedding plants awaiting

onward delivery

NURSERYJohn A C Weir

The HorticulturalEngineering SpecialistGroup and the South

Eastern Branch jointly visitedRoundstone Nursery recently.

Those who are old enoughwill remember UK beddingplant production, in the late1950’s and early 1960’s, as littlemore than a ‘cottage’ industry.At that time the remaining post-war austerities had finally beenshaken off; our economy wasbeginning to improve and thiswas one of the nascent sectorsof horticulture which was aboutto take off.As it turned out, wewitnessed a firm gradualexpansion of the bedding plantindustry which, in manyrespects, is still in progresstoday.The transformation froma low technology and highlylabour intensive operation towhat exists today, has largelyresulted from successfullybalancing the ‘supply’ and‘demand’ sides of the business.Plant breeding programmes,seed production technology,specialist subtrates, modularhandling, mechanisation and

automation, have all played a keyrole in both creating andsatisfying this expanding market.

There could hardly be abetter example, of how abedding plant producer hasprogressed from smallbeginnings to capture asignificant slice of this market,than Roundstone Nursery,based in Angmering,WestSussex. Originally established in1985, they set up as a specialistbedding plant production unit,supplying local retail outlets.Fred Milbourn, the first manager(now Managing Director), isalways a keen exponent ofexploiting new technology tomeet the growing demand forquality bedding plants. He hasbeen primarily instrumental intaking the Roundstoneenterprise from an originalglasshouse area of less than 1ha, employing a workforce often, to its present productionarea of approximately 12 ha,employing almost 100 full-timestaff.

The most recentdevelopment in this expansion

has been the opening of a new7.5 ha production unit(Newlands Nursery) nearChichester which has involved asubstantial investment inengineering technology.

Roundstone NurseryOur visit commenced at theRoundstone site which has beengradually developed andexpanded over the years, byincreasing the glasshouse areaon the land available. FredMilbourn explained that theaddition of the Newlands unithad given them the opportunity,not only of achieving thesubstantially increased outputtarget but also reorganisingtheir production operation intotwo separate phases.Roundstone has now beendevoted entirely to the initialplant and propagation, in which

seed-sowing and germinationtakes place in multi-cell trays;being grown on to a point atwhich the ‘plugs’ are ready totransfer to the second, finalphase, of the productionprocess at Newlands.

Transforming the seedsowing and pricking out ofseedling plants, arguably themost labour intensive manualoperation in commercialhorticulture, into a fullymechanised and, more recently,virtually automated process hastaken three decades ofdevelopment.At Roundstone,we were given a graphicdemonstration of the latestproduction line systems.Theseare designed to minimise labourinput using high speed precisionsowing and robotic plant plugtransfer. Labour input is nowlargely supervisory in the handsof skilled operators.The key tomechanised or automated seedsowing, has been in thedevelopment of pelleted andcoated seed which enablesseeds, irrespective of shape orsize, to be handled mechanically.

John Weir is Vice President of the IAgrE

and Chairman of the Horticultural

Engineering Specialist Group. E-mail:

[email protected]

INFORMATION

Horticultural Engineering SpecialistGroup and South Eastern Branch visit

9

This has paved the way for thedevelopment of precisionseeders, most of which operateby holding individual pelletedseeds by vacuum on a rotatingperforated drum or nozzlesplacing each directly into itsown compost plug, contained inmulti-plug trays.

At Roundstone, an automaticseed sowing line is capable ofsowing at a rate of 1200 traysper hour.The Roundstonepropagation system has beenstandardised by using expandedpolystyrene trays eachcontaining 264 or 405 plug cellsfor production from seed and126 cells for cuttings (a smallerand less automated part of thebusiness).These reusable traysare purpose designed for thecompletely automated sequenceof compost filling, sowing,watering, plug removal andstacking.

In the greenhouse, the trayare laid out either on benchesor the floor and covered withan unwoven polypropylenemulch which is removed shortlyfollowing onset of germination.At a later stage, when defectssuch as failure to germinate ornecrotic growth can be spottedin individual plugs, each batch oftrays is put through aprocessing lines where thedefective plugs are removed andreplaced with healthy ones,using robotic ‘finger’transplanters.This is an entirelyautomatic process, controlledby image analysis which hasproved to be one of the mostsuccessful recent developmentsfor increasing productivity, inwhat would otherwise be anextremely labour intensive andtedious operation; ensuringapproaching 100% occupancy ofviable plants in each tray.The‘replenished’ trays are returnedto the propagation area wherethey remain until the youngplants have developed a root,stem and leaf system sufficientfor their final transplanting into‘end packs’ and this is the pointat which the plug trays aretransferred to Newlands

Nursery.

Newlands NurseryThe one factor which singlesout Roundstone’s enterprise isthe high proportion of itscapital investment devoted tomechanisation and automation.Fred Milbourn remarked onhow important maintaining aclose liaison between himselfand the contractors (BrinkmanUK – agents for Visser, theequipment manufacturers) hadbeen, both at the planning andconstruction stages.This wasparticularly true at Newlands,where very large numbers ofplants had to be transplantedand transported, achievingmaximum space utilisation, ofgreat importance at this site,while minimising the handling ofbatches within the productionarea.

The 12 ha Newlands site,approximately 15 miles fromthe Roundstone Nurserylocation, was required toimplement the decision ofincreasing Roundstone’s annualoutput target to 60 millionplants.A 7 ha block of Venloglasshousing, provided with a 2ha service area, accommodating:• compost preparation and

storage site;• plug transplanting

equipment;• loading bay;• offices and• 7 million litre water storage

reservoir nearby.This has been the

culmination of a rigorousplanning programme, to createa highly mechanised productionsystem.

The stacked plug trays,transported by truck fromRoundstone Nursery, areunloaded and transferred tolines incorporating robotic‘finger’ transplanting systems,capable of working at a rate of40,000 plugs per hour. Here therooted plugs are removed fromtheir original trays andtransplanted into ‘end packs’filled with compost.These aremulti-celled expanded

polystyrene plant packs whichwill be familiar to all those whobuy bedding plants for gardencentres. Compost preparationor ‘mixing’ and tray filling iscarried out automatically on

separate lines, feeding directlyinto the transplanter lines.Thetransplanted end packs are thenautomatically stacked inpreparation for transfer to thenew glasshouse: where theystand, until ready for dispatchsome weeks later.

This 7 ha Venlo glasshouseprovides a single area capable ofholding up to 24 million plantsat any one time! With an eavesheight of 4.5 m, it canaccommodate thermal or shadescreens, overhead irrigation and

production lighting. But,undoubtedly, its mostinteresting feature – particularlyfrom an engineering viewpoint –is its unique plant handling andtransportation system. Clearly

an operation of this magnitude,with the prime objective ofminimal labour input whileproviding maximum flexibility,can only be achieved by a fullymechanised system. It isessential this system isstandardised on a modularbasis, capable of handling thecomplete range of plant speciesproduced at Roundstone. In theplanning of Newlands, it wasdecided to depart fromcontainer benching, moregenerally accepted for bedding

A rotating-drum vacuum seeder; the pelleted seeds are held ateach suction orifice as the drum rotates, releasing each row ofseeds in the appropriate cells as the plug tray passes below

Healthy seedling plugs being inserted by a robotic ‘finger’transplanter into the gaps left by the removal of defective plugs.Note: each cell in the plug tray has four vertical channelsarranged around its internal wall (see first row) which allow thefour transplanter fingers to penetrate to the bottom of the plugwithout disturbing the compost.


HORTICULTURAL ENGINEERING

10

plant production and adopt an‘on the floor’ system.Apartfrom lower cost, it provides thefacility for the rapidtransporting of batches ofplants, within the ‘standing out’area, using travelling gantries

handling purpose-designedcarrier trays – absolutelyessential for this scale ofoperation.The carrier traydimensions (1270 mm x 560mm) are based on the universalmodule of the Danish trolleytray, used throughout thehorticultural industry.This, easyto handle, carrier tray alsomaximises space utilisation atthe final ‘standing out’ stage,while providing a carryingcapacity of eight (4 x 2)standard Euro end packs.

The ‘standing out’ area,consisting of 52 bays, has anoverall maximum capacity of70,000 carrier trays exclusivelyhandled by a system of threegantry transporters.The first –known as the ‘robot’ – operates

within the bays, actually runningon track laid along the edges ofeach bay and powered by itsown internal combustionengine. It has a primary role oftransporting batches of carriertrays, a maximum of 48 at atime, within the ‘standing out’area.This semi-automatictransporter, works inconjunction with the other twoelectrically motorised ‘slave’shuttle transporters.The robotis also equipped with a built-inspraying system for fulfilling its

secondary role of liquidfertiliser and pesticideapplication.

The robot does have anoperator controlling its varioustasks but the shuttles work inan entirely automatic mode,being controlled by the robot.Running on a central gangway, atright angles to the bays, eachshuttle transports newly filledbatches of trays from theloading area, to a point oppositethe bay, wherever the robot islocated.The robot thenremoves its batch of trays (byrunning over the top of theshuttle) and transports them totheir designated location; thereverse process takes placewhen transporting the packsonwards.

Driverless shuttles, travellingbackwards and forwards,present a potential hazard toany obstacle; particularlyworking staff using the centralgangway. Both shuttles have

been equipped with proximitysensors which sense such anobstruction and halt the shuttleuntil it is removed.This wasinadvertently put to the testduring our visit where one ofthe shuttles fortunately sensedan obstruction of a humannature!

The importance ofmechanisation to theRoundstone enterpriseFrom seed sowing through todelivering the end product totheir retailing destinations, atthis scale, is a daunting logisticaloperation. Roundstone hasapplied an industrialisedapproach to their entireproduction system, with asubstantial investment in thisprogramme of mechanisation,automation and informationtechnology. Using this approach,it has been possible for them toachieve their ambitious annualoutput target of 60 millionplants at a consistently highquality which the bedding planttrade currently demands. Oneof the most significant benefitsaccruing, has been the dramaticimprovement in labourproductivity which hasincreased 40-fold sinceoriginally setting up business in1985!

Fred Milbourn gave us a firsthand account of the planningwhich had gone into the projectfrom its inception.We wereparticularly fortunate in that hismanagers from both sightsaccompanied, Ian Frame andSean O’Sullivan, as our guides,taking us through a veryinteresting day.

The ‘robot’, working in one of the bays, running at right anglesto the central tramway

Carrier trays loaded beneath the robot and suspended byhooks, two per tray handle; in the lifted position, about to beplaced on one of the shuttles; the spray lines and nozzles canbe seen attached to the gantry frame

Central shuttle tramway showing the two shuttles (right handforeground fully loaded with 48 carrier trays; right hand back-ground in left hand lane, parked in loading station)

11

PROFESSION

SOCIETY FORTHE ENVIRONMENT

(Soc Env)

IntroductionSince the early 1990’s,representatives from a numberof professional bodies withenvironmental interests havebeen meeting to discuss mattersof common interest and toexchange views andinformation.The discussiongroup was known as the Forumfor Environmental Professionals(FEP).

The transition of thisdiscussion group into a newumbrella body forenvironmental professionals wasinitiated by two past presidentsof the Chartered Institution ofWater and EnvironmentalManagement, Professor PeterMatthews and the late Dr GeoffMance, who proposed the needfor such an umbrella body andfor a new Chartereddesignation for environmentalprofessionals.As a result, after ashort initial period operating asan umbrella body known by theacronym CUBE, nineprofessional bodies with ashared aspiration to promote asustainable environment havecome together to form anumbrella body called the‘Society for the Environment’.

Other professional bodiesincluding the RoyalMeteorological Society have

taken part in the preliminarydiscussions to form theumbrella body and are expectedto remain connected with theactivities of the Society in thefuture.

“the start ofsomething big…[which] could make asignificantcontribution toregulating standardsfor the environmentalprofession”.Baroness Barbara Young,Chief Executive of theEnvironment Agency

The Constituent Bodiesrepresent approximately 30,000environmental practitionersdrawn from a wide range ofprofessions, each with a trackrecord of pre-eminence in itsparticular field and of particularachievements.This is a

substantial and diverse group ofpeople who in their workinglives confront a full range ofenvironmental issues.

The Society has beenformed to provide aninternationally recognisedprofessional qualification forenvironmental practitioners, theChartered Environmentalistqualification. More generally, theSociety aims to add to the skillsof environmental practitioners,thereby enabling them tocontribute more effectively tothe promotion of a sustainableenvironment. In time, theSociety will also provide anindependent and unbiasedforum for debate, creating theopportunity for environmentalpractitioners to speak with onevoice on environmental issues.

The Society was launched atthe ‘Environment UK’conference at Stoneleigh Park,near Coventry, in October

2002. In announcing theinitiative Baroness BarbaraYoung, Chief Executive of theEnvironment Agency, describedit as,“the start of somethingbig… [which] could make asignificant contribution toregulating standards for theenvironmental profession”.

The Society was formallyincorporated under theCompanies Act 1985 as acompany limited by guaranteeon 13 February 2003 withRegistered Company Number4665882.The Society is now inthe process of seekingrecognition of its particular rolein promoting goodenvironmental practice bypetitioning for the grant of aRoyal Charter of Incorporation.

The Society’s roleThe Society aspires to be theleading and co-ordinatingprofessional body in

The Society for the Environment is an independent umbrella body for environmental professionals.Atpresent, it is made up of nine professional bodies and learned societies involved in the environmentalsector, representing approximately 30,000 environmental practitioners drawn from a wide range ofprofessions.

Formally launched in October 2002, the Society aspires to be the leading and co-ordinatingprofessional body in environmental matters and a pre-eminent champion of a sustainable environment.The internationally recognised professional qualification for environmental practitioners of CharteredEnvironmentalist will be conferred on suitably qualified members of the participating professionalorganisations.

PROFESSION

12 LANDWARDS AUTUMN 2003

environmental matters and apre-eminent champion of asustainable environment.TheSociety will achieve this bynurturing and harnessing thecombined resources,knowledge, expertise andachievements of theprofessional and learned bodieswhich are its members.

The Society will foster aculture of inclusivity: theidentity of our ConstituentBodies will be maintained andtheir primacy as the centres ofexcellence within their fieldsrecognised and enhanced. Inaddition, the Society will ensurethat each individual member ofeach Constituent Body feelsengaged with the Society,whether or not he or sheaspires to be a CharteredEnvironmentalist.

The Society aspires tobe the leading and co-ordinatingprofessional body inenvironmentalmatters and a pre-eminent champion ofa sustainableenvironment

So what is a sustainableenvironment? Most of us knowinstinctively what we mean bysustainability, or rather a societywhich lives by sustainablemeans, but it is proving difficultto be precise in how this idealstate should be achieved.

Sustainable Development isthe means by which we willachieve this goal, but the paceand style of that development isvery much a function of the willand commitment of society and,in particular, organisations andindividuals within society. It isabout striving for a way of lifewhich has low impact but notlow output.

Sustainable developmenthas three interlockingcomponents – theenvironmental, social andeconomic.The Society isconcerned primarily with theenvironmental component,

which includes the effectiveprotection of the environmentand the prudent and efficientuse of natural resources.

The Society aims topromote a sustainableenvironment by buildingsustainability learning into theprofessional developmentprogrammes of its ConstituentBodies.This will add value tothe skills of the individualmembers of the ConstituentBodies, so that they will be ableto contribute more effectivelyto the development andmaintenance of sustainablecommunities.

Specifically, the Society willlicense Constituent Bodies toaccredit their individualmembers with the newqualification of CharteredEnvironmentalist.Thisqualification will be awarded bya process comparable to thatwhich exists in otherorganisations awardingchartered status to individuals.

Further, in time, the Societywill also provide anindependent and unbiasedforum for debate, creating theopportunity for environmentalpractitioners to speak with onevoice on environmental issues.Because of the inclusive natureof the Society, where there isno consensus, the Society willpublish a range of views.

SustainableDevelopment is aboutstriving for a way oflife which has lowimpact but not lowoutput.

The Society will add valueto the work of the ConstituentBodies by creating theopportunity for them to worktogether as a team, thusdemonstrating one of the mostimportant values of sustainabledevelopment – co-operation.The Society believes thatindividual members ofConstituent Bodies will beempowered by thisarrangement and by the

Chartered Environmentalistqualification.

The Society’sMembersConstituent BodiesThe membership of the Societycurrently comprises the nineConstituent Bodies. Over time,the Society intends to admitmore Constituent Bodies.Indeed, several substantialprofessional bodies haveindicated an interest inbecoming Constituent Bodies inthe immediate future.

In line with theSociety’s culture ofinclusivity, over timethe Society intends toadmit more memberbodies.The work andidentity of all theSociety’s memberbodies will bemaintained.

The Society intends allConstituent Bodies to seek tobecome licensed to accredittheir individual members withthe new qualification ofChartered Environmentalist.

Associate BodiesThe Society also intends toadmit to membership otherorganisations sympathetic tothe aims of the Society but whodo not meet the criteria formembership as a ConstituentBody (these organisations willbe known as ‘AssociateBodies’).The RoyalMeteorological Society hasalready committed to apply tobecome an Associate Body if aRoyal Charter is granted.

Unlike Constituent Bodies,Associate Bodies will not beeligible to be licensed toaccredit their individualmembers with the CharteredEnvironmentalist qualification.

The CharteredEnvironmentalistqualificationOnly full voting members oflicensed Constituent Bodies will

be eligible to be awarded theChartered Environmentalistqualification.The CharteredEnvironmentalist qualificationwill not be conferredautomatically or easily andcandidates will be required todo something in addition totheir Constituent Bodymembership.

The Society has beenformed to provide aninternationallyrecognisedprofessionalqualification forenvironmentalpractitioners –CharteredEnvironmentalist

The qualification will beawarded by a processcomparable to that which existsin other organisations awardingchartered status to individuals.The criteria are to be based onknowledge of, competencies inand engagement with goodenvironmental practice, ncludingthe promotion of a sustainableenvironment.Also, candidateswill be required to agree tocomply with a code of practice.

A two-stage approach toqualification has been adopted.First, a candidate will have topre-qualify with appropriatelearning in the work of theConstituent Body to which thatindividual belongs; that learningwill be a mixture of knowledge(possibly including academicstudy) and competence(experience in a chosenenvironmental discipline).Second, the candidate mustdemonstrate through aProfessional Review Interviewthat he is actively engaged ingood environmental practice,including the promotion of asustainable environment.

Pre-qualificationrequirements• The candidate must be a full

voting member of aConstituent Body at a gradeapproved by the Constituent

13

Body and the Society.• The candidate must have

achieved at least twelve unitsof learning. For thesepurposes one year ofsuccessful study counts astwo units and one year ofwork experience in therelevant subjects counts asone unit.

• The candidate must have at

least four years of relevantwork experience.

• The period of relevantexperience must include theacquisition of specialistknowledge and thedevelopment of skills andcompetencies needed topractise in a specific area ofinterest of a ConstituentBody; there must be a clearrecord of progress, certifiedby a supervisor or mentor.

• Candidates with no acceptedacademic qualifications willhave to demonstrate thatthey have been employed inwork relevant to the seniorgrades of the ConstituentBodies for at least twelveyears.

Requirements for theprofessional reviewThe candidate must:• produce a written report

that demonstratescompetence, knowledge andengagement in goodenvironmental practice,including the promotion of asustainable environment in

accordance with the learningsyllabus;

• attend an in-depthProfessional ReviewInterview conducted by atleast two qualifiedCharteredEnvironmentalists;

• be engaged in professionaldevelopment that must havestarted at least four years

before the professionalreview and a verified recordmust be provided (if theConstituent Body does nothave a professionaldevelopment process inplace, the candidate maysubmit a retrospectiverecord, but the Societyprefers its ConstituentBodies to have a professionaldevelopment process);

• give a commitment tocontinuing professionaldevelopment and review; and

• sign an agreement to complywith a code of practice.The professional review

requirements have been framedwidely.This should ensure thatmany other membership-basedinstitutions are able to relatethem to their own particulardiscipline or field of expertise.The challenges of goodenvironmental practice requirethe combined talents of manydifferent types of practitionersand it is the intention of theSociety to offer recognition andguidance on continuingprofessional development to

the widest possible range ofpeople.

ManagementorganisationBoardThe Board has a policy andscrutiny role. It is intended thatthe Board will meet at leastthree times a year. EachConstituent Body is entitled tonominate two individuals to actas Board members. Boardmeetings are chaired by theelected Chair of the Society.

Management CommitteeA Management Committee willbe responsible for makingproposals to the Boardconcerning the day-to-daymanagement of the Society,including finance and resources,environmental policy, publicrelations and communications.It is intended that theManagement Committee willmeet at least once a quarter. Itis proposed that theManagement Committee bemade up entirely of members ofthe Constituent Bodies.

Chief Executive & SecretariatIt is proposed that the Societywill recruit a Chief Executive tolead the organisation, initially ona part-time basis. In time, it isenvisaged that such ChiefExecutive will recruit a smallteam.

Registration AuthorityOn the grant of a RoyalCharter, a RegistrationAuthority will be created.TheAuthority will be responsiblefor issues relating to the grantof the CharteredEnvironmentalist qualification. Itis intended that the RegistrationAuthority will meet at leastonce a quarter. It is proposedthat the Registration Authoritybe predominantly made up ofmembers of the ConstituentBodies.

General MeetingsThe Society will hold an annualgeneral meeting once a year to

approve its annual report andaccounts and to transact anyother relevant business.Extraordinary general meetingswill be held as and whenrequired.

Each Constituent Body isentitled to nominate twoindividuals to act as itsrepresentatives at generalmeetings. However, aConstituent Body may onlyvote by one of itsrepresentatives in generalmeetings. In contrast, althougheach Associate Body is alsoentitled to nominate twoindividuals to act as itsrepresentatives at generalmeetings, such representativeswill not be entitled to vote atsuch meetings.

General meetings will bechaired by the elected Chair ofthe Society.

FinanceThe Society has been fundedinitially by contributions fromeach of the Constituent Bodies.During the calendar year 2003,the Society will also be fundedby the Joining Fees payable bynew entrant ConstituentBodies.

The Society’seducational roleWith the increasing importanceof high standards ofenvironmental practicedemanded by the public,emphasised in such world wideconferences as the Rio EarthSummit and Johannesburg 2002,the education of all thoseworking in the environmentalsector will continue to grow inimportance.The Society aims toadd to the skills ofenvironmental practitioners,thereby enabling them tocontribute more effectively tothe promotion of a sustainableenvironment.As a result, theSociety believes there is a linkbetween providing educationand training for environmentalpractitioners and creating abenefit for the public at large.


TrainingAll the Constituent Bodies playan important role in theeducation and vocationaltraining of their individualmembers. Some have their ownqualification courses, and manyencourage, support, andaccredit courses at first degreeand higher degree levels atUniversities and other Collegesof Higher Education.

The Society will encouragethe development of academiccourses of the highest qualitycovering a range ofenvironmentally based subjects.Completing certain of thesecourses will enable candidatesto satisfy the academicrequirements for the award ofthe Chartered Environmentalistqualification.

ContinuingProfessionalDevelopmentAll environmental practitionersneed to keep themselves up todate in their knowledge andunderstanding both of their

own specific area of expertiseand of wider environmentalmatters.All CharteredEnvironmentalists are requiredto complete a programme ofcontinuing professionaldevelopment through theirConstituent Bodies. Suchprogrammes require CharteredEnvironmentalists to satisfy aminimum requirement forcontinuing professionaldevelopment activity.

The Society will assist theConstituent Bodies to providethe necessary content for suchprogrammes. Should aChartered Environmentalist failto complete such a programme,he or she may be subject to adisciplinary procedure whichmay ultimately lead to theChartered Environmentalistqualification being withdrawn.

Dealings withGovernment andother organisationsThe Society will create theopportunity for environmentalpractitioners to speak with one

voice on environmental issues. Itwill act as the principal focalpoint for Constituent Bodieswhen dealing with externalorganisations where a collectiveresponse is required.This wouldnot, however, preventConstituent Bodies expressingtheir own views.

The ManagementCommittee will be responsiblefor the Society’s external affairs.The Committee will ensure thatthe process of handling externalaffairs is not haphazard butstructured.

The environment and howit is managed is a recurring issuefor politicians in the UnitedKingdom, in the EuropeanCommunity, and in other partsof the world.

The Society is committed toproviding factual informationincluding relevant advice andassistance to all politicians andpolitical parties with regard tothe promotion andadvancement of goodenvironmental practice, tosafeguard the environment and

maintain and enhance publicconfidence. Such advice andinformation will include actingas a consultee on draftdocumentation emanating fromgovernment and other statutorybodies. In an early initiative, inOctober 2002, a response wassubmitted on behalf of theSociety to DEFRA concerningthe disposal of sewage sludge.

International links In time, the Society aims tofoster links with environmentalbodies based overseas, buildingupon the strong links that theConstituent Bodies have withsuch organisations.

Registered Office:Society for the EnvironmentSuite 138 Ebury StreetLondonSW1W 0LUTel: 020 7730 5516Fax: 020 7730 5519Web: www.socenv.orgRegistered Company No.4665882

ORGANIC BENEFITS

Kent-based organicfertiliser manufacturer,Ecosolve Ltd, has

opened a subsidiary office inIndia, Eco-Indorganics (EIO),following advice from TradePartners UK – the governmentorganisation that providessupport services for UKcompanies trading overseas.Thecompany is also in the processof launching an innovative newproduct after committing£50,000 to the venture.

The connection with Indiawas developed afterparticipating in a Trade PartnersUK supported trade mission.Outward Trade Missions

provide an extensiveframework of both practicaland financial help for UKbusinesses travelling abroad aspart of a group to marketsoutside Western Europe, topromote UK goods andservices.

During the mission,Ecosolve’s managing director,Roger King was given thechance to present his ideas at aseminar held in Delhi in front ofpotential business partners.TheTata Energy Research Institute(TERI) expressed an interest inlinking up with Ecosolve andthey are now developingtogether a range of ‘designer’

organic fertilisers for specificcrops.The first of these is oneof the tea gardens in Assam.

Mr King said,“The replacingof chemical fertilisers withorganics helps to achieveEcosolve’s overall aims ofreducing the effect of globalwarming and of alleviating ruralpoverty.Avoiding the burning oftwo tonnes of fossil fuels toproduce one tonne of chemicalnitrogen fertiliser preventsmillions of tonnes of CO2 beingemitted to the atmosphere, andthe re-fertilisation of the soil,depleted by decades of use ofchemical fertilisers will lead toincreased crop yields, improved

crop quality and, therefore asubstantial raising of farmer’sincomes.”

Negotiations are at anadvanced stage for a significant,million dollar plus, Britishinvestment in the Punjab StateOrganic Farming project. EIOwill be able to introduce intoIndia the innovative processesand components developed byEcosolve in their R&D work inIndonesia over the last tenyears.At the same time EIO willassist in the marketing of thefinal produce by acting as abridge between the Indianproducer and the Europeanfood importer.

UK organic fertiliser manufacturerleads the way to environmentallyfriendly crops in India

PROFESSION

1

M E M B E R S H I P

THE NEWS L E T T E R O F THE I N S T I T U T I ON O F AGR I C U L TUR A L ENG I N E E R S

Bimonthly AUTUMN 2003

Recognising the need toaccommodate those senior

members of the engineeringprofession who did not have therequired academic backgroundcurrently required forregistration as a CharteredEngineer, the EngineeringCouncil introduced the ‘SeniorRoute’ to registration.

Intended for those whoseresponsibilities would make itimpractical and inappropriate forregistration via the EngineeringCouncil exam or via the MatureCandidate Route, this routerequires candidates todemonstrate their fitness forregistration by virtue of thecompetence which enables themto perform their current roles.

The IAgrE MembershipCommittee is pleased toannounce that Richard Hughes(FIAgrE), Managing Director ofHugh Pearl (Land Drainage) Ltdis the first IAgrE member totake this route to CEngregistration.

Richard, a member of IAgrEsince 1972, has spent most if notall of his working life with HughPearl (Land Drainage) Ltdbecoming Managing Director in1981. He has been heavilyinvolved in agricultural

contracting trade organisationsand in 1984, together with threeother drainage contractors, wasinstrumental in theestablishment of the LandDrainage ContractorsAssociation.

As is so often the case,Richard was in a position ofresponsibility – managing anorganisation whilst at the sametime being actively involved inmajor engineering project designand implementation – and so didnot have the time to develop anapplication via the MatureCandidate Routes (MCR) or

study for, and sit, the EngineeringCouncil examinations.

Richard is to becongratulated on hisachievement.

By definition, this route is atransitory route. Existing(younger) practising engineerswho do not have the educationalbase necessary for registrationhave the opportunity to developtheir portfolios for the MCR orto study for the EngCexamination.Thus, this route wasonly made available for a periodof five years.All registrationsmade by this route will need to

have been completed bySeptember 30th 2005.

Typically, candidates will • have held a senior

engineering position for aminimum of seven yearsnecessitating an involvementwith significant financial andengineerinpersonnelresources

• be able to demonstrate theircompetence to practise at alevel which clearly meets orexceeds the requirements forInstitution Fellowshiphave a minimum of 20 yearsof employment in anengineering environment

• be over 45 years of age.If any one wishes to have

further information on thisroute, please contact theMembership Secretary: email:[email protected].

AdmissionsAssociateB O Adigun (Nigeria)W A Bird (Wiltshire)R G Ryan (Warwickshire)S Salawu (Nigeria)G West (Cambridgeshire)Y K Yiu (Hong Kong)

StudentKing’s College, London:G J Caplen

Royal Agricultural College:J S MacGregor

Walford & North ShropshireCollege:C H AllenR K DearnaleyJ HoodG W NorburyS D PriceT R Radmore

TransfersMemberR Cole (Norfolk)W J Copeland (Co Armagh)

N J Penlington(Nottinghamshire)

EngineeringCouncilRegistrationsCEngP W Amos (Edinburgh)A D Gregory (Bristol)D W M Pullen (Bedford)

IEngB G F Mathew (London)

A FIRST FOR IAGREIAgrE Fellow achieves Chartered Engineer registration via the ‘Special Route to Registration for Senior Engineers’

MATTERS

MEMBERSHIP CHANGES

NEWS for MEMBERS

MEMBERSHIP MATTERS AUTUMN 20032

Dear Sir,Getting all sides of Industry

working togetherI am writing in response toyour article in the EarlySummer issue of Landwardsregarding the high age of theaverage engineer in ourindustry today. I believe that theonly answer to this decline ininterest of our subject, is tocreate a positive response andquickly.Today’s engineers muchmaximise their skills, gain a fewnew ones and go out andattract new blood quickly.

It is universally agreed, I amsure, that there is a shortage ofskilled personnel in theengineering sector of industry.As reported in the article: ‘Theaverage age of a mechanic inour industry is 53 years old’.Asthe ‘old school’ retire, feweryoungsters are ready to pick upthe baton.

The reasons are complexbut I will highlight what I feelthey are in the main. Firstly, it isnot cost effective to take onapprentices and undergraduatesand, with a lack of publiclyowned industry, few places areavailable for the would-be fitter,or mechanic. Secondly,mechanical engineering isunfashionable, it is seen as anout-of-date industry to be in. Imust agree that on the face ofit, this appears to be true.Themedia rarely publicise a greatengineering feat these days andwith the decline in the oncegreat British engineeringindustry still very apparent,(even in the displays of theNational Science Museum), ithardly seems to be thedirection to go in.Today’s‘disposable society’ also appearsto the uninitiated to be againstbasic engineering principles.Thirdly the potential earningsof the skilled fitter, ormechanic, lack the differentialwith other manual workers thatthey once enjoyed.This islargely due, I feel, to the

engineering unions of thenineteen sixties. In their rush torecruit more members and sogain more power, they relaxedthe entry requirements. Initially,semi-skilled workers wereallowed to join; then shortlyafterwards, almost anyonecould enjoy the benefits ofbeing with a major engineeringunion. Of course, when voteswere needed on importantengineering issues, theengineers were out-voted bytheir non-skilled brethren.Asissues concerning wageincreases and structures of paywere voted on, slowly butsurely the differential betweenunskilled and skilled workerwere eroded. Graduates, ofcourse, recognised the trendsaffecting the engineeringindustry and fought shy ofbecoming part of a decliningindustry; they saw littleopportunity in traditionalengineering and lookedcarefully at other ways todevelop their careers.Thosewho did choose to major inengineering, found fewopportunities and manymigrated to other disciplines,such as productionmanagement or research roles.

The companies that aresaving money by not taking on

apprentices andundergraduates, are facing ahugely expensive future, sadly,so are the few that are takingapprentices andundergraduates, because thereare increasingly, less and lessskilled personnel to go round.Those that have recognisedthat this problem is occurring,are saying:“Things will inevitablychange in time because, the fewskilled personnel left will beable to command a high wage,which will attract others intothe industry.Things will turn fullcircle.” Personally I am not atall sure that this will be thecase.

As an engineer in modernindustry, I have many roles toplay. I am sure this is true ofmany of today’s engineers. Inmy role as a trainers’ trainer, Ihave been looking for ways toprevent the ‘skill shortageeffect’ from hitting myemployer. Over the past fewyears, I have been instrumentalin developing an ‘Asset CareProgram’. I am sure that this isone of the few ways forwardand perhaps the easiestdirection to go in from thepoint we are at now, which Ifeel is ‘beyond the point ofbalance’, in respect of the skillsprogrammes of the past.A

return to the traditionalapprentice programme is simplynot viable; they just never werecost effective and I am not toosure that they were that goodanyway! What we must aim for,is to employ the ‘cream of thecrop’ of today’s youngsters, inan enhanced version of thetraditional apprenticeprogramme.This must be madea ‘lucrative position’ and paidaccordingly, none of the £2.10shillings a week that I was paidthroughout my ownapprenticeship.When thesehighly skilled apprentices finishtheir term, their skills must be‘maximised’ by being given an‘experience term’.At theconclusion of this term, theyshould be trained further in theart of training others to a highstandard.The people that theywill be training will not beother apprentices but adifferent type of machineoperator.

This machine operator hasbeen singled out, or indeedemployed, because they haveshown a reasonableunderstanding of engineeringpractices. I am sure we all agreethat many ‘unskilled persons’have a degree of engineeringability, perhaps they servicetheir own vehicle, some may

LETTER TO THE EDITOR

Askham Bryan CollegeAskham BryanYorkYO23 3FR

Cranfield University SilsoeBedfordMK45 4DT

Duchy CollegeRosewarneCamborneCornwallTR14 0AB

Harper Adams UniversityCollegeNewportShropshireTF10 8NB

Myerscough College

Myerscough HallBilsborrowPrestonLancashirePR3 0RY

Oatridge Agricultural CollegeEcclesmachanBroxburnWest LothianEH52 6NH

Pencoed CollegePencoedBridgendCF35 5LG

Reaseheath CollegeReaseheathNantwichCheshireCW5 6DF

Scottish Agricultural CollegeSAC Ayr CampusAuchincruive EstateAyrKA6 5HW

Sparsholt CollegeSparsholtWinchesterHampshireSO21 2NF

Wiltshire College – LackhamLacockChippenhamWiltshireSN15 2NY

Writtle Agricultural CollegeChelmsfordEssex

ACADEMIC MEMBERS

3

NEWS for MEMBERS

even carry out complexrepairs on them, they mayshow aptitude in other ways,perhaps by an engineeringassessment test.Thisassessment could be madeby the engineer, or at leastconfirmed by him, one of theextra burdens on a modernengineer using a system suchas this. Once chosen, trainingshould be on an ongoingbasis and they should becontinually assessed untilthey reach their fullpotential.This, of course, willvary from person to person,but it should not be impededin any way, as this can have adetrimental affect.

The engineers task,therefore, is becoming anabstract one. Carefulassessment, planning andtraining is crucial to buildinga first class engineeringworkforce.The engineer’srole has to change in themodern scheme of things, hisburden of responsibility isincreasing a hundred fold bytoday’s constraints andexpectations.Assessment ofmachinery suitable for thisasset care must be carriedout, a breakdown of taskssuitable for an unskilled, orsemi-skilled person to carryout must be grouped intotraining modules. Graduatesthat would be engineersmust therefore be extremelycompetent in recognisingpotential and their analyticalskills must also be on ahuman level, as well as on atraditional engineering level.

Manuals must be carefullywritten for every task, bothfor training purposes and forreference. If care is taken onthe way these are writtenand presented, a great dealof time on training and re-training can be saved. I havealso found that a carefullywritten check-sheet can notonly be a great diagnostic aidbut also increase theusefulness of an operatorand give an indication of the

depth of understanding thatthey have of their machine.Theengineer, therefore, has got tobe a writer and/or editor, toensure that a high standard ofprinted matter, or softwarebased material is produced andmaintained.

A by-product of this assetcare programme has beenincreased productivity due tothe operator having a sense ofownership of the machine theyare using. Recognised incidentsof sabotage in order to gainextra breaktime seems to havevanished (a recent DTI reportput this at 10%+ in a recentpress release). I also introduceda wish-list covering operations,design changes and operatordevelopments, for theoperators and trainers tocomplete.This has been auseful tool in decidingmodifications and techniquechanges and has resulted inincreased productivity.

Yours sincerely Geoff [email protected]

Autoguide Equipment LtdStockley RoadHeddingtonCalneWiltshireSN11 0PS

Douglas Bomford Trust16 The OaksSilsoeBedfordMK45 4EL

Bomford Turner LimitedSalford PriorsEveshamWorcestershireWR11 5SW

John Deere LtdHarby RoadLangarNottinghamshireNG13 9HT

FEC ServicesNACStoneleigh ParkKenilworthWarwickshireCV8 2LS

G C Professional Servicesfor land-based and relatedindustriesHighdown CottageCompton DownWinchesterHampshireSO21 2AP

Law-Denis Engineering LtdMillstream WorksStation RoadWickwarWotton-under-EdgeGloucestershireGL12 8NB

David Ritchie (Implements)LtdCarseview RoadSuttiesideForfarAngusDD8 3EE

Rotomation LtdSummerwood LaneHalsallOrmskirkLancashireL39 8RH

White Horse ContractorsLtdLodge HillAbingdonOxfordshireOX14 2JD

COMMERCIAL MEMBERS

News of MembersOlayinka Ayeni has recently taken up an appointment as theAgricultural Engineer at Zartech Agricultural Farm at Ibadan.

David Spencer has retired from Spencer E.C.C. Ltd andMargaret will be retiring shortly.They have sold the farm in westWales and have moved back to Abergavenny.Their new addressis Croesonnen Cottages, Hereford Road, Mardy,AbergavennyNP7 6HT.Tel: 01873 850596 Mobile: 07831 221820.The trainingcompany is TREE of KNOWLEDGE and is based at the aboveaddress and the telephone number is 01873 852499.

Paul Brooks resigned as the General Manager of the MasseyFerguson distributor for East Africa last year and has movedback to the UK to develop his business interests here. Paul hasbeen offered the opportunity of becoming a Harley-Davidsonmotorcycle dealer.

Peter Hickman has left Wm Bain & Co in Zimbabwe and hasbecome the General Manager of the Massey Fergusondistributor for East Africa in place of Paul Brooks. He will beresponsible for the franchise business in Kenya,Tanzania andUganda.

Adeniyi Talabi has recently retired from the Civil Service ofthe Federal Government of Nigeria where his last position wasDirector of the National Food Security Department in theFederal Ministry of Agriculture. However, he says that he intendsto take up any fresh professional challenges that may come hisway.

Tony ChestneyWrite to Tony with your news! His address is: 32Beverley Crescent, Bedford MK40 4BY


NEWS for MEMBERS

INSTITUTION of AGRICULTURAL ENGINEERS, WEST END ROAD, SILSOE, BEDFORD, MK45 4DU,UNITED KINGDOM. Tel: 01525 861096 Fax: 01525 861660

Produced by: Land Technology Ltd, Edinburgh Printed by: Barr Printers, Glenrothes

The Engineering Council (UK)has published the Specificationfor the standards which willreplace SARTOR 97 as the basisfor recognising ProfessionalEngineers and EngineeringTechnicians in the UK.

Launching the Specification,EC (UK) Chairman, Sir ColinTerry, paid tribute to thepainstaking work of the draftinggroup led by University ofNorthumbria Vice-Chancellor,Kel Fidler. Sir Colin said,“Wehave high hopes that this newstandard will help to ensure theUK continues to be recognisedas one of the leading engineeringnations of the 21st century”.

Main ChangesMonths of extensive debate haveproduced consensus on anumber of significant issues.Thespecification emphasises thatengineers (and technicians) mustdemonstrate competence beforeregistration. It also notes anumber of significant changesincluding:removal of artificial entryrequirements to accreditedcourses;agreement to use outputstandards as a basis foraccreditation;increased flexibility in educationalrequirements for CEng; andrationalisation of procedures forcandidates without standardqualifications.

There is also wide agreementthat future requirements shouldbe presented in a moreaccessible form than at present.

EC (UK) will also encourageemployers and Institutions toaddress process, with a view tospeeding up and making moretransparent the means to achieveregistration, particularly byspreading good practice in

accrediting graduate training anddevelopment schemes.

RevalidationThe Specification also addressesthe question of revalidation ofregistration. It proposes thatsystems for revalidation shouldbe established for those whoneed or wish to demonstratethey have maintained theircompetences.Andrew Ramsay,Executive Director of EC(UK),said “Since effective revalidationcan be costly, this service willinvolve additional expense to theRegistrants who take it up, butwe might reasonably expect thisto be defrayed by the employer.”

Programme forImplementationThe profession’s agreement onthe Specification launched asummer of intense activity, toturn the Specification intoworking documents foremployers, institutions anduniversities. Five Task Groups

were established in particular toensure that the output measuresadopted have wide support,including from employers andengineering academics.As aresult, four documents wereenvisaged, aiming for completionthis autumn: UK-SPECrequirements for ProfessionalEngineer for student andemployer audiences;• UK-SPEC requirements for

Engineering Technician forstudent and employeraudiences;

• requirements for PEI’s to holdlicenses to admit registrants;and

• accreditation requirements foreducation institutions andemployers.

What didn’t changeThe successful and widely-supported 4-year integratedMEng will continue to provide afast track route for high abilitycandidates for CEng.Thereremain just three categories of

registration: Chartered Engineer,Incorporated Engineer andEngineering Technician.A reportreviewing the scope for aRegister of “ProfessionalTechnologists” is still inpreparation by ETB – theEC(UK) Board have undertakento consider this when received.Development of the review hasinfluenced the Working Group,but there was widespread andvociferous support – fromindustry, universities, andregistrants – for retention of theIEng title.

While the focus, title andmanagement of EngineeringTechnician registration has notchanged, EC(UK) intend toensure it embraces a growingdemand from industry by fullyrecognising new opportunitiesoffered by ModernApprenticeships and othervocational routes into jobs withsignificant engineeringresponsibilities.A separatepublication aimed squarely atpotential Engineering Techniciansand their employers willdemonstrate the significanceplaced on this category ofregistrant.

LONG SERVICE CERTIFICATESName Grade Date of Anniversary50 yearsDavid John Balmforth Calverley CEng FlAgrE 13 Oct 2003lan Constantinesco CEng FlAgrE 13 Oct 2003

35 yearsJames Robert Poolman EngTech MIAgrE 19 Sep 2003Sidney Walter Reginald Cox CEng HonFlAgrE 10 Oct 2003lan Matthew Urwin MIAgrE 10 Oct 2003Anthony Victor Bashford EngTech MIAgrE 10 Oct 2003James Allan Gibson FlAgrE 10 Oct 2003Christopher John Baker CEng FlAgrE 10 Oct 2003Alistair Lee lEng MIAgrE 10 Oct 2003John Alexander Douglas MacCormack lEng MIAgrE 10 Oct 2003lan Charles Smeaton IEng MIAgrE 10 Oct 2003Michael Patrick Bernard Eur Ing CEng FlAgrE 10 Oct 2003Christopher Rupert Garner CEng FlAgrE 10 Oct 2003

25 yearsAndrew Charles Knight CEng MIAgrE 29 Aug 2003

AGREEMENT ON NEW STANDARDS FORREGISTRATION

15

A DAY IN THE LIFE OF.......

HALF A CENTURYOF FARMING

John Moffitt, CBE

Born in 1929, I find as I getolder that I spend moretime reminiscing about

the past rather than speculatingon the future.There is one verygood reason – I have a mind fullof memories belonging to themost prosperous periods ofBritish Agriculture.

The post war years of the1950’s saw a groundswell ofchange and expansion driven bya government that saw the needfor Agriculture to play a vitalpart in the economy of thecountry after the Second WorldWar.

Leaving school in 1946 toreturn home to milk cows wasthe natural path for a farmer’sson, particularly as NationalService was compulsory exceptfor the essential services whichincluded agriculture. I soon start-ed to play my part in the chang-ing aspects of farming.

George Potts, the teenageson of our shepherd, this yearreceived the RASE Long Service

Award for over 50 years of serv-ice with the same employer.George played his part in thechanges that took place fromhaymaking to silage and thebinder to combine. In 1950, aNew Holland pick-up baler wasbought and within a decade,farming practices on our farmhad completely changed.We alsoinvested in an ICI tray-type grassdryer to provide even betterquality forage for our expandingherd of Pedigree Friesians but itwas a lengthy and tiring job atonly 2-3 cwts an hour (0.1-0.15t/h).

A herd of 70 cows averaging1,150 gallons (5,000 litres) wasconsidered exceptional and wetopped the herd averages for theFour Northern Counties – a farcry from the 10, 000 litre rollingaverage my son achieves with his330 cows today.

In 1950 there were 196,000milk producers in the UK withan average herd size of 14 cows.This number has now shrunk to

less than 20,000 and still declin-ing with an average herd size ofalmost 80.At the end of the war,milk rationing remained in placeuntil 1952 and the demand wasfor more and more of everythingthat British farmers could pro-duce.

The National Herd still con-tained over 30% Shorthorn butcross breeding to Friesians andthe rapid expansion of artificialinsemination (AI) saw a dramaticincrease in yield and a high milkprice – in real terms almostthree times of that paid today.The milk price was controlled byGovernment with a review tak-ing place on an annual basisinvolving a battle between theNational Farmers Union,Politicians and The MilkMarketing Board, placing produc-ers very much in the drivingseat.

Turnips and mangoles provid-ed a sizeable part of the dairycow’s diet but quickly declined asthe techniques of silage makingimproved. Cereals began to playan increasing part in our opera-tion as our farming continued toexpand to over 1,000 acres (400ha). Prices were exceptional

‘In 1950 there were 196,000 milk producers in the UK withan average herd size of 14 cows.This number has nowshrunk to less than 20,000 and still declining’


A DAY IN THE LIFE OF.......

16

compared to today’s marketand I well remember the firstyear we exceeded an averageof 2 tons an acre (5 t/ha) ofwheat in 1960 and our firstyield in excess of 3 tons anacre (7.5 t/ha) in 1959, a varietyaptly named N59.After being at home for 15years, life started to change forme in the 1960’s as I began totake an increasing interest inresearch becoming involvedwith the Agricultural ResearchCouncil (ARC) which contin-ued for a period of 25 years. Iwas initially involved with theDairy sector then with thebroader issues of Agricultureunder the new organisation, theBBSRC, playing a part in theresearch programmes atBabraham, Roslin, Compton andSilsoe. I was Chairman of the

Governing Body for theResearch Institute at Silsoe for7 years and faced the difficultand challenging times of fundingdifficulties as well as continuingto develop a number of diversebusinesses at home.

Premier BreedersAs AI replaced the need forbreeding bulls in the dairy herdand this lucrative market wentinto decline, I joined with twoother breeders, Claybury andMontgomery, to develop acompetitive service to theMMB who had, by Governmentdecree, established a monopoly.Premier Breeders, our compa-ny, secured 15% of the AI mar-ket and pioneered the firstNational Embryo TransferService with seven satelliteoperational centres.We contin-ued to develop the techniquesof non-surgical transfer and thefreezing of embryos way aheadof the rest of the world, thanksto the help from research cen-tres such as Babraham and

Roslin.As Company Chairman,the business was operatedfrom my home farm at Peepyuntil we purchased a farm forthe company in the 1970’s,eventually selling out the totalbusiness in 1990 to Genus, thesuccessor body to the MMB.

Hunday ElectronicsAnother field that had alwaysinterested me was to improvethe efficiency of dairy cowmovement in the increasinglylarger herds that were develop-ing. Hunday Electronics wasestablished in the early 1970’sas one of the first in the fieldwith automatic identification,winning silver awards for ‘Outof Parlour Feeding’, ‘In-ParlourFeeding’ and ‘Automatic MilkRecording’ over a period of adecade before developing auto-

matic sow feeding systems. In1991, the business was sold toOsborne Industries in the USA.

Vintage machineryWhy I should begin to take aninterest in old agriculturalequipment in 1964 is a bit of amystery but as with mostthings in life it is about oppor-tunity.

One day on my journeybetween farms, I noticed a1940’s Oliver ‘70’ tractor bythe roadside.To cut a longstory short and after somehaggling, I purchased it for£8.0.0 and took it home toWest Newham Farm where Iwas now living with my wifeand family and restored thisbeautiful six-cylinder petrolengine machine.

Another farm that was pur-chased in 1965 was Westsidewith an old set of traditionalbuildings which provided anideal resting place for furthervintage purchases.At one stageover 200 tractors and engines

brought the accommodation tobursting point.

Diversification became agrowing interest and in 1979,with considerable help fromthe National Tourist Board withthe development, we were priv-ileged to have the QueenMother open the ‘NationalTractor and Farm Museum’. Itook advantage of theGovernment’s ‘job creationservice’ and built workshops toprovide facilities for the essen-tial restoration work.

In 1971 the Museum wonthe coveted ‘New Museum ofthe Year Award’ for the UK andwas reserve to the ‘Museum ofEurope’ the following year.Dividing my time betweenfarming and the different busi-nesses I had developed was dif-ficult but it taught me one

important lesson and that wasthat good loyal people wereessential to success. If any ofmy staff showed ability, flareand hard work, they were giventhe responsibility to run thatbusiness as their own. I wasextremely lucky to attractexcellent people into thesepositions and by now farmingover 2,000 acres (800 ha), dele-gation became a key element inrunning a successful operation.

Milk processing ventureUnhappy with the monopolypowers of the Milk MarketingBoard (MMB), I decided toenter a new field of marketingour own milk. Grants were stillavailable and with two farmingpartners we bought secondhand pasteurising and packagingequipment in order to retail‘fresh from the farm’ cartonedmilk to outlets in the NorthEast from our Bays Leap Farmon the outskirts of Newcastle.This venture was perhaps theshortest and least profitable

venture I had yet undertaken.The competition for the liquidmarket was fierce and withinfive years, we sold out to oneof the competitors realisingthat diversification is not alwaysas profitable as forecast.

RetirementSo now at the age of 74 andhaving successfully transferredthe farming business to my sonsome 12 years ago, I can reflecton an interesting lifetime infarming and I am pleased that Ihave not had to adapt to thepressures of today where oneperson now milks 330 cowsand, despite more than dou-bling the yields of both milkand cereals, prices havedropped to half of what theywere during my farming years.

Today I am just as busy as

ever – we have a large gardenwhich I enjoy and continuewith my interest in anythingold.This year in particular I cel-ebrated both the 100th birth-day of my favourite tractor, thelvel, raising £100,000 for charityas well as celebrating 50 yearsof marriage.

I have kept a full page diaryfor over 55 years and am cur-rently trying to chronicle theminto a shortened version.As weget older, our memories areprone to exaggeration but thewritten word never changes. Ihave published two books sinceretirement and am currentlywriting the history of ourHunday Herd and the evalua-tion of today’s modern dairycow.

I feel extremely fortunateto have had such an interestinglife in farming and, although Iam occasionally pessimistic ofthe future, I am sure thatAgriculture will continue toplay an important part of theeconomy of our great country.

‘I feel extremely fortunate to have had such an interesting life in farming and,although I am occasionally pessimistic of the future, I am sure that Agriculture willcontinue to play an important part of the economy of our great country.’

17

RISK ANDENGINEERING

Engineers are accustomedto dealing with uncer-tainties in the properties

and behaviour of materials.Each discipline has developedover time, methods and proce-dures to continuously enhancethe safe and reliable operationof products and processes.Thesuccesses of these proceduresis evident all around us,whether in respect of smallelectronic devices, interconti-nental flight in twin-engine civilairliners, domestic appliancesor countless other examples.The risk management method-ologies employed to achievethis level of performance areoften very sophisticated andinvolve logic, judgement andcomplex numerical procedures.

When the need for anengineering product is obviousand universally agreed, then thetechnical risks are the crucialones and the engineer can han-dle them in relative isolation.This was probably the case inearlier days in respect of theprovision of basic infrastruc-ture such as drinking watersupply or electricity. However,today, with technology availableto meet most basic needs,engineering products have tobe justified in terms of addedvalue to an enterprise and itscustomers and have to beacceptable to the communityat large in terms of safety, envi-ronmental, public health andpolitical impact. Risk is notreadily tolerated and mistakeslead to recriminations. Errorimplies blame with both politi-cians and lawyers, seemingly,obliged to find a guilty party.The development of this ‘blame

culture’ has a damaging effecton the morale of those organi-sations in the firing line, inhibit-ing learning, innovation and risktaking.

Despite the dramaticimprovements in the perform-ance of engineering products,recent history is littered with aseries of apparent failures.Weread of cost and time overrunsin projects such as the JubileeLine, the West Coast Railwayupgrading, and the new air traf-fic control centre at Swanwick.The media fills from time totime with stories about thedanger of rail travel, the risk tohealth of cell phones or elec-tric power lines, the environ-mental dangers of geneticallymodified (GM) plants andnuclear power is presented asan unacceptable evil.While insome of these situations thereare undoubtedly elements oftechnology inadequacy or fail-ure, the main difficulties andproblems lie at the interfacesof technology with commercial,political and social constituen-cies.

The uncertainties inherentin these external constituen-cies are quite different in kindfrom the uncertainties thatengineers traditionally dealwith in addressing technologyissues.They are much morequalitative than quantitativeand they embrace a whole raftof cultural and emotional fac-tors that often contradictapparently obvious logic.Engineers find this a difficultdomain to deal with. If theyrespond simply using theirtraining in quantitative and logi-cal thinking they alienate other

stakeholders in projects.This‘cultural divide’ must bebridged to avoid project failureand mutual recriminations. It isvital to find ways to reconcilethe difference between ‘objec-tive risk’ based on scientificmeasurement and basic engi-neering principles and ‘subjec-tive risk’ perceived by the non-technical public at large.This

can only be achieved if thevalidity and limitations of eachapproach is well understood.

Three reportsThe Royal Academy ofEngineering has produced aseries of three reports cover-ing different aspects of engi-neering risk management inorder to show how this cultur-

PUBLICATION

Table 1 Definitions of commonly used terms in risk management


PUBLICATION

al divide might be bridged.Thereports provide the engineeringcommunity with guidance onhow to take other stakeholdersinterests into account.They alsoprovide business leaders, policymakers and managers withinsight into how engineeringactivities should be integratedinto their decision making andoperating procedures.The three reports can be foundon the Academy’s website atwww.raeng.org.uk/news/publica-tions/reports entitled:• The societal aspects of risk• Common methodologies for

risk assessment and manage-ment

• Risks posed by humans forthe control loop‘Risk management’ has

recently taken centre stage inthe strategic thinking of mostmajor organisations. UK thinkingon the matter is encapsulated inthe ‘Turnbull Report’ publishedin 1999.

It is interesting to observethat the risk management mod-els developed in the financialand business arenas have a lot incommon with traditional engi-neering methods of dealing withthe uncertainties in propertiesand behaviour of materials.However, these methods havebeen extended to ensure astructured methodology fordealing with human behaviour aswell as information uncertainty.The first report addresses thecritical issues surrounding ‘soci-ety’s’ perceptions of risk. Itexplains why the engineer’s tra-ditional numerical approach,based on statistics, is quite inad-equate in dealing with the realhuman emotions that come intoplay in addressing technology.For too long, science and engi-neering have seemed to blamesociety for not understandingthe benefits that they offer.While there is a very strongcase for improving the level ofscience education and under-standing, the report illustrateshow engineers need to makemajor changes in their approachto addressing the legitimate

concerns of community stake-holders in their projects.This isreferred to in the summarywhere it is stated that“Engineers need to understandhow groups in society developperceptions about the riskinessof engineering projects andprocesses and what these per-ceptions depend on”.This cul-tural construction of risk isbecoming more widely acceptedand frequently emerges in thedebate over issues that areunresolved or un-resolvable bythe scientific evidence.

The second of the Academyreports on ‘CommonMethodology’ builds on thesedevelopments and shows howengineering risk managementcan be integrated into an enter-prise’s corporate risk manage-ment policies and procedures. Itrecommends a generic strategicapproach within which the moretactical technical processes canbe accommodated. It emphasis-es that while a structuredapproach to risk management isessential, it must not be allowedto become routine or mecha-nistic. Independent assessmentsshould be made at critical deci-sion points to maximise theintegrity of the process.

The majority of the acci-dents seen today are due to

human or organisational errorsrather than technical failures.While further improving relia-bility and extending automationcontinues to be a priority forengineers, much more attentionneeds to be given to the humanfactors involved in operatingand maintaining engineeringproducts.The third report inthe series, ‘Humans in theControl Loop’, looks at thisissue in some detail.

It concludes that engineersneed to be much more awareof the available research onhuman behaviour and to incor-porate its lessons into thedesign of control rooms, driverscabs, and the other interfacesbetween humans and machines.Major differences are observedbetween different industrial andservice sectors in theirapproach to dealing with humanfactor issues.The report arguesthat there are great gains to bemade by a much more coordi-nated and determined sharingof experience across sectors.The key issues involved in shar-ing and exchanging best prac-tice are summarised. It shouldbe noted that these apply quitegenerally and across manyother fields than simply humanfactors.

The issues dealt with in all

three reports are complex andthe working groups who devel-oped them are not claiming tohave produced the definitivetexts.All see the need for fur-ther work and appreciate thattheir recommendations willrequire significant effort on theparts of all the target audiencesto implement. One key elementin this is the need for a com-mon language that can meet thespecific needs of the engineerbut at the same time is mean-ingful to the layman, so thateach can participate in the dia-logue.

In publishing these reportsthe Royal Academy ofEngineering is grateful to all ofthe members of the workingparties who contributed totheir preparation.Whether theywere Fellows of the Academyor not, they were generous inproviding data and views basedon a very considerable wealthof experience.We believe thatthe output will be of value toeducators, practicing engineersand those who employ andmanage them as well as policymakers and opinion formers.John Turnbull, FREng, is theleader of the ‘Risk Project’.

19

NEWS SCAN

CONTACT

The Welding Institute (TWI)has been associated with theCertification Scheme forWelding and InspectionPersonnel (CSWIP) for over 30years.A major part of thisscheme involves thecertification of weldinginspectors.

Recently, a completelyseparate organisation in theUK, the British Institute ofNon-Destructive Testing(BINDT), has introduced itsown certification scheme forwelding inspectors as part oftheir Personnel Certification inNon-Destructive Testing (PCN)scheme.

Potential users of WeldingInspector certification should

be aware that the engineeringexperience requirement foraccess to certification is of amuch shorter duration in thePCN scheme compared toCSWIP, and there is nominimum age at whichcertification may be obtained.

Neither TWI nor CSWIPsupports, recognises orendorses the PCN weldinginspector scheme in any way.

The CSWIP WeldingInspector Certification Schemeis unaffected by theintroduction of the PCNscheme. CSWIP will continueto offer a means ofdemonstration of competencefor welding inspectors which isrecognised by all relevant

authorities and clientsthroughout the world,accredited by UKAS, andbacked by the technicalresources and quality standardsof TWI. CSWIP is the only UKcertification scheme recognisedby the European WeldingFederation and theInternational Institute ofWelding.

The following is an extractfrom a recent letter receivedfrom Professor Sir BernardCrossland CBE, FRS, FREng,FIAE, MRIA.

“My attention has beendrawn to the possible reduction inthe experience required for accessto certification as a weldinginspector. Based on my experience

of investigating accidents anddisasters arising from defectivewelds, I strongly believe anydiminution of the experiencerequired is to be deplored. If weldsof acceptable integrity are to beproduced then there is a strongcase for enhanced standards ofeducation, training andexperience.”

Penny Edmundson, TWI Ltd,Granta Park, GreatAbington, Cambridge CB16AL, UK. Tel: +44 (0)1223891162. E-mail:[email protected]

Certification of Welding InspectorsACCREDITATION CONFLICT

CONTACT

Almost 1200 sprayershave been tested duringthe first six months of

the scheme according NSTSManager, Duncan Russell.

‘All the sprayers on thedatabase have passed, but 50%of them have required somerepair or rectification before apass certificate can be given’says Mr Russell. ‘The mostcommon fault found is leaks anddrips from the applicationsystem, something operatorscan cure for themselves’ hecontinues.

The National Sprayer TestingScheme launched at Smithfieldstarted testing sprayers officiallyon 1st January this year.TheNSTS is one of the three leadcomponents of the VoluntaryInitiative, along with theOperators register (NRoSO)and CPMPs.The NSTS target isto have tested 5,000 sprayers by31st March next year.

Mr Russell agrees there isstill some way to go to achievethe target. ‘We’ve a healthynumber of machines beingoffered for test even at this timeof the year and with January –March the busiest time fortesting, I’m reasonably confidentwe will be close to the target’he says.

The most important thing isto get enough testers and testcentres established. ‘Currently’,continues Mr Russell, ‘there are74 test centres and, with thetest being available through theirbranches and through Case,John Deere and Hardi dealers,this gives a total of 474locations where the NSTS testcan be obtained’.

‘I’m looking for further testcentres and anyone who isprofessional in the sprayerbusiness should seriouslyconsider being part of thescheme’ he says. ‘Sprayers are

becoming more sophisticatedand it’s important that theirmaintenance and testing shouldbe carried out by dedicated andqualified sprayer specialists’.

‘There is a fear held bymachine owners that we areasking machines to performbetter than they did when new’says Mr Russell. ‘That is certainlynot the case. Machines aresubjected to a series of simplechecks to make sure they areworking as designed and aresafe for both the operator andthe environment.The testconsists of checks on 40 itemson the sprayer, 30 of which itmust pass to receive a passcertificate, the other ten arecautionary note items and it isup to the owner whether theseitems are put right’.

‘To help with machinepreparation a check sheet isavailable from the NSTS websitewww.nsts.org.uk’ says Mr

Russell. ‘Regular inspections bythe operator can keep themachine functioning correctlyand accurately and save muchdowntime and possibleapplication inaccuracies.’

Figures show that only 5%inaccuracy could cost as muchas £5.60/hectare in winterwheat, with much more in rootcrops. ‘Downtime is anincalculable cost’ says MrRussell, ‘with a tight weatherwindow or disease pressure, anyloss of spraying time can bevery costly indeed’.

For further details on thescheme or on becoming asprayer examiner, contactNSTS, Samuelson House,Paxton Road, Orton Centre,Peterborough PE2 5LT. Tel:01733 362925. E-mail:[email protected] Web:www.nsts.org.uk

National Sprayer Testing Schemereports results of its first 6 months

EQUIPMENT SAFETY


PRODUCT NEWS

20

Buhler Group is aworldwide supplier ofmachinery for processing

chocolate, pasta, flour andother bulk materials in the foodindustry.The company is also amajor competitor in thechemical process engineering,bulk solids handling and diecasting industries.With such adiverse business model, one ofthe company’s major challengesis trying to manage the vastamount of productdevelopment data that itgenerates.

The scale of Buhler’sbusiness is impressive, withover 1.4 million parts in over700 product lines installed inthousands of plants around theworld.Traditionally, like manycompanies, separate groupsmanaged the design informationon all these parts. Buhler used avariety of manual methods tokeep track of productdevelopment, while automatedsystems ran independently fromone another with littleconsistency, continuity orconnection. In thisenvironment, employees oftendid not know where dataresided and wasted

considerable time huntingfor information, workingwith non-concurrentrevisions and recreatingexisting but misplaceddocuments.

To add to the problem,Buhler’s global operationsrequired the sharing of datawith 40 affiliated companies andmore than 80 subsidiariesworldwide. Bottlenecksoccurred in trying to worklong-distance withsubcontractors supplying partsfor Buhler equipment and withthe engineering consultants,architectural firms andconstruction companiesdesigning and building the largeplants where Buhler machinesare installed. For the most part,information was shared via 2Ddrawings, reports and otherpaper documents, with all theusual delays and confusion offinding, copying, mailing, faxingand distributing hard copies.

Food for thoughtAware that the lack of efficientdata exchange was hamperingthe company’s efficiency andpotential development, Buhlerdecided to overhaul and

streamline its businessoperations. Instead of trying tomanage information throughseparate and disjointedsystems, the company chose toconsolidate its data into a singleproduct lifecycle management(PLM) system from SmarTeam.The system enables computeraided design (CAD) files and awide range of projectinformation to be archived andreadily exchanged, not onlyamong different groups,departments and facilities butalso with outside companies.

“PLM is a strategiccomponent of our enterpriseInformation Technology (IT)infrastructure,” explainsKarlheinz Ribar, the projectmanager at Buhler overseeingthe PLM implementation.“Buhler is building a worldwidecollaborative productdevelopment system thatextends into the supply chainand tracks critical informationthroughout the productlifecycle.”

Ribar has set a tough aim

for the system – to reduce thetime to market new productsby 30%, increasing the speed ofdelivery to customers andstrengthening Buhler’s positionas a market leader.

The system connects all ofBuhler’s subsidiaries via datareplication and web servers,with over 1000 peopleworldwide using SmarTeam forsystem design and projectmanagement.As SmarTeam isavailable online, employees canaccess information remotely viathe Internet. Different divisionswithin Buhler, subcontractors,outside consultants and processplant architects can exchangeinformation electronicallywithout the delay of handlingpaper documents.

Recipe for successBuhler has plans to linkSmarTeam to the company’sSAP financial system (SAP is theworld’s largest enterprisesoftware company whichprovides companies of all sizeswith business solutions). It also

Productlifecyclemanagement –the rightingredient forBuhler

INFORMATION TECHNOLOGYIngredients mixing on anindustrial scale

plans to process planning andcomputer numerical control(CNC) programming systems inmanufacturing this way

Data from areas such asengineering, manufacturing,sales and service will all beincluded in a directory for eachjob, tracking the course of eachcustomer installation fromconcept development throughdetailed design, engineeringchange, field maintenance andeventually decommissioning.

With its far-reaching plans,Buhler has put itself at theforefront of companies that arebroadening the scope of PLM.Historically most at homewithin engineering departmentswhere it was used to managedrawings and CAD files, PLMhas reached other areas ofbusiness that are now wakingup to the benefits of thisenterprise-wide access toinformation. For Buhler, PLMmeans the difference betweenbeing one of a crowd andhaving a real, measurablecompetitive advantage.

“In this sense, the mostvaluable benefit PLM brings toBuhler is that it serves as anenabling technology for greatercollaboration,” explains Ribar.“Not only among separategroups, departments and

facilities within the companybut also in the supply chain andamong the partner companiesthat make up our extendedenterprise. In that respect, PLMis absolutely essential for us tocompete effectively in theworld of e-commerce.”

Pick n’ mixAccording to Ribar, a number ofreasons favoured the selectionof SmarTeam.

The software is widely usedand supported internationally,so Buhler facilities around theworld can implement it.Thescalability and economy of thesoftware guaranteed that smallsubsidiaries and individualgroups could easily implementthe solution. In addition,SmarTeam could be easilycustomised for Buhler’s specificprocesses and procedures.

As it is based on MicrosoftWindows, the software usesfamiliar features such as drag-and-drop, cut-and-paste andintuitive menus with whichusers are already familiar andso can become productive in amatter of days rather thanmonths. It also operates withinAutoCAD, Mechanical Desktopand other leading midrangeCAD solutions, so users canaccess data and perform PLM

operations without exiting theirCAD system.

The web technologyprovided by SmarTeam enablesBuhler to implement its plansfor distributed facilities to gainaccess to product data.

Ribar says that Buhler alsoneeded a system that couldhandle different types ofdocuments created in MicrosoftOffice applications such asWord and Excel, in addition toCAD files. Moreover, the PLMsystem had to have thecapability of interfacing withdifferent application programsin manufacturing, sales andother areas.

Piece of cakeFollowing a pilot phase,SmarTeam went into operationwith 50 users in the pasta,chocolate and thermalprocesses departments atcompany headquarters inUzwil, Switzerland. Usersconsisted of designers managingtheir CAD files as well as non-CAD users, including managersand others in the designapproval process who use thesystem to view drawings in thereview cycle.

“Project leaders,department supervisors andother managers who have no

AutoCAD knowledgewhatsoever are able to viewand release designs quicklythrough the use of viewertechnology built intoSmarTeam,” notes Ribar.

Initial results in the pilotrollout phases of theimplementation demonstratesignificant savings in time andcosts for information anddocument retrieval and in theelimination of redundant effortsby re-using existing data.

“We have nowimplemented the system intotwo of our affiliated companiesin Germany: Buhler-Bindler andBuhler-Frisse,” Ribar explains.“Additionally, we are in theplanning phase for two bigEuropean sites: Buhler-Braunschweig and Buhler-Madrid.”

Eventually, the PLM systemwill co-ordinate the flow ofinformation to and fromsubcontractors providing partsand subsystems, as well as tooutside consultants performingengineering services. Buhleralso hopes that PLM willfacilitate the exchange ofinformation with largearchitectural, engineering andconstruction firms to helpdetermine plant layouts andhow these large facilities will bebuilt.

Proof of the puddingUsing a module withinSmarTeam, a link has beenestablished between PLM andBuhler’s SAP financial system totrack man-hours, project costs,invoices and other information.This capability gives managerson-line access to up-to-dateinformation on each projectand eliminates the need torecreate data for the financialsystem that already exists in thePLM.

Buhler also plans to linkSmarTeam with productionprocess planning and CNCprogramming systems inmanufacturing. In this way, partgeometry stored in SmarTeamCAD files can be used by these

21

Fusilli drying; SmarTeam users,following a pilot phase, wentinto operation in severaldepartments at Companyheadquarters to review a singleproduct lifestyle management(PLM) system fromSmarTeam, which has beenused to consolidate data,enabling CAD files and a widerange of project information tobe archived and exchangedamong groups, departments,facilities and outsidecompanies.


NEWS SCAN

22

systems as input for machiningparts and fabricating assemblieson the shop floor.

In addition to CAD files andengineering drawings, a widerange of other types ofinformation will be archived inthe PLM database, includingdocuments created in MicrosoftOffice applications such asWord and Excel and well asphotos, videos and other typesof graphical information.

“In this way, the system willhandle design data as well asengineering changes,correspondence, bids, quotes,proposals, service histories andother relevant information foreach project, giving engineers,managers and others acomplete history of eachproject from start to finish,”says Ribar.“PLM enables us tomanage projects throughout thecomplete lifecycle.”

Company profileSmarTeam Corporation Ltddevelops, markets and supportsrapidly implemented, yet totallycustomisable, product lifecyclecollaboration solutions thatdrive efficiency, quality andresponsiveness for customercentric organisations and theirvalue chains. Founded in 1995, itis one of the fastest growingcompanies in the PLM marketwith over 2000 customersworldwide and a broadsolutions portfolio that enablesmanufacturing organisations andtheir supply chains to efficientlymanage and collaborate onproduct information fromconcept through realisation.SmarTeam’s solutions helpcompanies gain improvementsin product quality, reduce costs,expedite project turnaround,comply with industry standardsand shorten ‘time to market’.

Contact: Fiona Caton ofSmarTeam Europe Ltd. Tel:+44 (0)1455 618709 E-mail:[email protected] Website:www.smarteam.com

CONTACT

AWARD

John Deere’s manager,technical services, DavidPreece has received aspecial combine harvesterengineering award from thecompany, in recognition ofhis major contribution tothe design of the PowerSeparator in WTS (walkertine separator) combineharvesters, and to otherharvesting projects.

Incorporated asstandard equipment on allJohn Deere 9000 WTSSeries combine harvesters,which were introduced forthe 2002 harvest season,the power separator lifts,stretches and opens thestraw mat to allow moreefficient grain separation,compared with the previouscross shaker design used inZ Series and 2200 Seriesmodels.

It was the result of a sixyear engineering projectwith the specific objectiveof improving combineharvester performance inUK conditions.The designutilises a combination ofconventional and tineseparation technology todeal more efficiently withgreen and damp straw, andenhance grain separation onthe straw walkers.

The four stage threshingsystem begins with a large660 mm diameter cylinderand long 750 mm concave.A rear beater and secondconcave provides additionalthreshing, and propels thecrop to the extremely long11-step straw walkers.Further separation isprovided directly above thestraw walkers by the tinepower separator, whichconstantly and gently liftsand combs the straw mat to

release trappedgrain.

Keyadvantages of thissystem are thatthe full crop flowarea is used forthreshing andseparation, somaximisingcombineharvesterperformance; it’seasy to changefrom crop tocrop; and there’sa low specificpowerrequirement, which meanslower fuel consumption.

“Our initial test designsadapted a baler pick-up,which was grafted into theback of the combineharvester above the strawwalkers so that we couldlearn more about thestretching and pullingactions on the straw,” saysDavid Preece, who hasworked in service andcustomer support for JohnDeere Limited in the UKfor over 30 years,specialising in harvestingequipment.

“The main problems wefaced were the increasedmoisture and friction levelsin green straw, typical of UKvarieties that were beingbred to become riper in thehead but stiffer in the straw.This meant that grainkernels were not beingseparated as efficiently aspossible, so contributing togreater losses out of theback of the combineharvester or the need toreduce operating speed.“Essentially the powerseparator allows fasterforward speeds and reduces

grain losses, and overallperformance of thecombine harvesters hasimproved by between 10and 13 per cent comparedwith previous similar sizedmodels. Not only does thenew design enhanceperformance in UKconditions,” he adds.

“This awarddemonstrates John Deere’scommitment to developingand testing combineharvesters for UKconditions, and the valuablecontribution our UK fieldand service staff make tomachinery innovation anddesign,” says Peter Leech,John Deere’s manager,customer support.

“The power separatorunit has been verysuccessful and well acceptedby customers, contributingto John Deere’s increasedshare of the Europeancombine market.”

Jonathan Henry, JohnDeere Limited. Fax: 0044 1949 860490. Web:www.johndeere.co.uk

David Preece with his John Deerecombine harvester engineering award –a commemorative pewter plate – inrecognition of his major contribution toharvesting equipment design duringmore than 30 years with the company

John Deere ‘CombineHarvester Engineering Award’

CONTACT

23

MORE INFORMATION

One fifth of EU employees – 32million people – are exposed tocarcinogenic agents; 22% ofworkers inhale fumes andvapours for at least a quarterof their working time; two-thirds of the 30,000 mostcommonly used chemicals inthe EU have not been subjectedto full and systematictoxicological tests; forsubstances with knowntoxicological risks, as few as12% of firms comply with riskprevention regulations.

The first pan-Europeancampaign to reduce the risks ofchemicals, biological agents andother dangerous substances atwork – hazards that affectaround a quarter of the EU’s150 million employees – isbeing promoted by EuropeanAgency for Safety and Health atWork. Cancers, asthma andneuro-psychiatric problems arejust some of the illnesses thatcan be caused by the 100,000chemicals marketed in the EU,as well as biological agents.

According to research, 21%of EU employees are exposedto known or suspectedcarcinogens, such as benzene(in fuel) and crystalline silica(construction materials), while22% of workers inhale fumesand vapours for at a least aquarter of their working time,including organic solvents,wood dust and welding fumes.In addition, 16% of employeeshandle or come into contactwith dyes, pesticides,Chromium VI (via wet cement)and other dangeroussubstances for similar periods,either directly or throughcontaminated surfaces andproduction processes. Sectorsmost at risk range fromconstruction and agriculture to

printing, cleaning, health careand automotive mechanics.

These risks are heightenedby inadequate regulatorycompliance and information.One study, for instance, foundthat only 12% of firms wereaware of their regulatoryduties. Moreover, a separatestudy revealed that 20% ofSafety Data Sheets supplied bymanufacturers of hazardoussubstances contained errors.

The health impacts aresignificant. Research has shownthat 4% of all cancers, forexample, are work-related andthat 10% of employees contracteczema. In addition, studiessuggest that one third of allcases of adult-onset asthma arecaused by workplaceexposures. Occupational skindiseases alone, which oftenforce employees to changejobs, including 10% ofhairdressers, are calculated tocost the EU 600 million ayear. Occupational asthma isestimated to cost the EU 400-800 million.

The human and financialcosts, however, are likely to bemuch larger. Existing data isbased on studies of substanceswith known toxicities.However, two-thirds of the30,000 most commonly usedchemicals in the EU – around20,000 substances – have notbeen subjected to systematictoxicological tests andassessments. Only newchemicals notified since 1981must undergo these tests,although the EU is developing astrategy to systematically assessso-called ‘existing’ chemicals.

“Dangerous substancescontribute significantly to the350 million days lost throughoccupational ill health in the EU

and to the seven million peoplesuffering from occupationalillnesses,” says AnnaDiamantopoulou, EuropeanCommissioner for Employmentand Social Affairs.“The Agency’scampaign, together with EUinitiatives, including our recentWhite Paper on a Strategy fora Future Chemicals Policy, areimportant steps in dealing withthis severe, but often hidden,problem.”

Pat Cox, President of theEuropean Parliamentcomments:“The use ofdangerous substances in theworkplace is commonplace formillions of EU workers. It isimportant that campaigns suchas these convey the message toboth workers and citizens thatdangerous substances need tobe handled with care both inthe workplace and at home.This campaign is not onlyimportant in raising awarenessbut provides us with advice andgood practice on how toeliminate or minimise theserisks.The important role of themedia in assisting in this taskcannot be underestimated.”

“I am very pleased toannounce that the EuropeanWeek for Safety and Health atWork has developed into thelargest safety and health eventin our region, including not onlythe 15 EU-Member States butalso all Candidate Countriesand all EFTA countries,” saysHans-Horst Konkolewsky,Director of the Agency.“Dangerous substances need tohandled with care – this is thekey message of our 2003campaign. In many cases safesubstitutes for dangeroussubstances do exist, forinstance to replace organicsolvents. If this is not possible,

exposure can be eliminated orreduced through efficientcontrol measures.We hope tocommunicate these messagesalong with a lot of goodpractice information toworkplaces all across Europewhere dangerous substancesare handled.”

To support this drive, theAgency’s campaign, which willform the heart of its EuropeanWeek on Safety and Health atWork in October, will provide arange of information about therisks and solutions throughvarious media.These willinclude information packs in allofficial EU languages, posters,leaflets and a multilingualwebsite athttp://osha.eu.int/ew2003/.TheAgency, which acts as aEuropean portal forinformation on occupationalsafety and health, will alsoannounce at the Week’s closingevent in November the winnersof its European Good Practiceawards for organisations thathave most successfully tackledthe problem of dangeroussubstances via preventivemeasures, risk awareness,substitution and othertechniques. During October2003, events will be organisedacross Europe to bring thecampaign to life in allorganisations, large and small,public and private.

European Agency for Safetyand Health at Work, GranVia 33, E-48009 Bilbao,Spain. E-mail:[email protected]: +34 94 479 4383.

First pan-European campaign to combat risksof dangerous substances at work

TOXICOLOGY AT WORK


NEWS SCAN

RECYCLING INITIATIVE

The Environment Agencyis leading a partnershipdedicated to ridding

Gloucestershire of the 2,000tonnes of plastics it is estimat-ed that the county’s 7,000farms produce every year.

The trial project is a jointventure between theEnvironment Agency, Farmingand Wildlife Advisory Group,Plasmega Ltd, NationalFarmers Union (NFU), StroudDistrict Council, Serviceteamand the Recycling Consortium.It will collect the plastics fromthe farms and will use aprocess pioneered by PlasmegaLtd to recycle it into itemssuch as fence posts, buildingaggregate, pipes and drain cov-ers. Doing this will mean thatthe plastics waste, mainly inthe form of silage wrap, will nolonger have to be buried or beburnt.

The Gloucestershire FarmPlastics Recycling Scheme fea-sibility study, was set up in2000 by the EnvironmentAgency and the Farming andWildlife Advisory Group(FWAG) to investigate envi-ronmentally sustainable dispos-al options for waste plasticproduced by agriculture.

The situation they werefaced with was both complexand discouraging.There wasonly one factory in the UKwhich could deal with contam-inated plastics, and that was inDumfries.

Therefore, one of the firstthings the scheme investigatedwas a company which coulddeal with the wet, dirty plasticwhich was collected from thefarms. Research identified acompany called Plasmega,based in Sharpness, which haddeveloped a new method of

processing the waste plasticwithout the need for washingit.

Once Plasmega agreed toaccept the waste and joinedthe study, the partnershipbegan the work of investigatinghow the plastic should be col-lected, what type of materialcould be recycled and possiblemarkets for the end productPlasmega produced.

Using a typical refuse col-lection vehicle (which couldcompact the plastics andsqueeze out any excess water)was discovered to be the bestway of collecting the wastefrom farms. Other organisa-tions, including the NationalFarmers Union, Stroud DistrictCouncil, Serviceteam and theRecycling Consortium havesince become involved.

A trial will now be run totest the practicability of collec-tion of farm waste plastic andto generate data on the finan-cial viability of such collection.

The project has fourobjectives to:• develop and demonstrate a

viable method of farm plas-tics collection;

• generate data on the opera-tional and financial perform-ance of the collectionscheme;

• promote farm plastics recy-cling amongstGloucestershire farmers;and to

• use the data and experiencegained during the pilot trialto design a sustainable farmplastics recycling schemefor Gloucestershire.The project, which will be

funded by the EnvironmentAgency Recycling Consortium,Plasmega Ltd and CoryEnvironmental Ltd, will aim to

collect up to 500 tonnes ofwaste plastic fromGloucestershire Farms duringa one year period.

Speaking about the project,the Environment AgencyManager for Lower Severn,Harvey Bradshaw, says:“Themanagement of farm plastic isan area of major concern tothe Agency and representativesof farming and industry.

“The Government hasalready published its ‘WasteStrategy 2000’, which set outits objective of reducing theamount of plastics waste beinglandfilled and work to gainvalue from it. Projects such as

this will deal with the problem,providing a cleaner, more envi-ronmentally friendly solutionto the question of what to dowith farm plastics.”

Collections can bearranged through FWAG.Charged at £10 per tonne.Tel: 01452 627487.Further details from OliverBlackburn, TheEnvironment Agency,Sapphire East, 550Streetsbrook Road, Solihull,B91 1QT. Tel: 0121 7115855.

Green project set upfor black plastic

CONTACT

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MORE INFORMATION

The Health and SafetyExecutive (HSE) launched itsnew Accident Book – approvedby the InformationCommissioner – at the RoSPAConference for OccupationalHealth and Safety.The newbook will help organisations tocomply with Data Protectionlegislation.

The new publication, theHSE Accident Book (BI510), hasbeen revised as most existingaccident books allow personaldetails and information to beseen by anyone reading ormaking an entry in the book.The previous version, producedby the Department of Work

and Pensions (DWP), and othersimilar books do not complywith the Data Protection Act1998 (DPA). In revising theAccident Book, DWP haspassed responsibility forproduction to HSE.

The InformationCommissioner, whose role is toenforce the DPA, has ruled thatbusinesses must change theiraccident book to comply withthe DPA by 31 December2003.The new design allows foraccidents to be recorded, whiledetails of individual(s) can bestored separately in a securelocation.

In addition to recording

incidents, the new book alsocontains useful information onfirst aid and how to managehealth and safety information tohelp prevent accidents fromhappening in the first place.

Kate Timms, HSE DeputyDirector General, who spoke atthe conference on buildingpartnerships with keystakeholders, said of the newAccident Book:“The book isbeing launched as a tool to helporganisations in terms of bothhealth and safety and DataProtection compliance.”

All organisations now haveunder three months to meetthe new Data Protection

regulations, which will beenforceable from 31 December2003.

Copies of The HSE AccidentBook ISBN 0 7176 2603 2price £4.75 plus VAT areavailable from HSE Books,PO Box 1999, Sudbury,Suffolk, CO10 2WA. Tel:01787 881165. Fax: 01787-313995. HSE pricedpublications are alsoavailable from all goodbookshops.For enquiries call HSE’sInfoLine. Tel: 08701 545500.

HSE brings accidents to book

DATA PROTECTION

MORE INFORMATION

The characteristichedgerows ofWarwickshire, which

form such a vital part of itslandscape, are featured in a newvideo promoting conservationthrough the traditional craft ofhedgelaying.The video has beenproduced by the NationalHedgelaying Society with finan-cial assistance from Defra’sRural Enterprise Scheme (RES),and was launched at the RoyalShow.

Hedgelaying is the historicpractice of cutting and manag-ing hedges and has developedover centuries to maximisetheir efficiency as stockproofbarriers. Each region’shedgerow style developedaccording to the characteristicsof its landscape and farming,and around 30 regional stylesare recognised.

The video, which aims toraise the skills and knowledgeof landowners, farmers and

others with an interest inhedgelaying techniques, is intro-duced by HRH the Prince ofWales and featuresWarwickshire’s ‘Midland’ styleamong eight regional styles ofparticular interest. It covers:• the history of hedgelaying;• the importance of hedges in

the UK landscape;• the role of hedges in nature

conservation;• regional styles of hedgelaying;basic techniques; andhealth and safety.

The Midland style, alsoknown as Bullock style, is athick, high hedge, which pre-dominantly uses thorn.Traditionally made in cattle-rearing country, it is designedto keep large heavy bullocks intheir field.The brush faces theanimal side to prevent themeating the new growth, andstrong ornate bindings runalong the top to hold the hedgein place.

The basic principles ofhedgelaying are common toevery regional style. Each stemof the hedge is partially cutthrough, allowing it to be lay-ered at an angle, and securedto create a stockproof barrier.The hedge is still able to liveand grow and is rejuvenatedfrom the base as it throws upnew shoots.

Apart from its practicalapplications, hedgelaying makesa valuable contribution to thehealth of the countryside. Ithelps preserve hedges andextend their lifespan, enhancingthe appearance of the country-side, providing importantwildlife habitats, acting as greencorridors for birds, mammalsand insects, and preserving thediversity of farmland species. Italso keeps alive an importanttraditional rural skill and con-tributes to the rural economy.

Emily Ledder, from Defra’sRural Development Service,

commented:“Hedgelaying canbring lasting landscape andwildlife benefits and is a tradi-tional economic and craft activ-ity in many parts of ruralBritain.

“One of the main aims ofthe Rural Enterprise Scheme isto support sustainable andenterprising rural economiesand communities.We hope thevideo will improve understand-ing of an important agriculturalskill, and so bring benefits tothe wider rural economy, aswell as those involved in agri-culture. It will also help keepalive one of the key tools forconserving the wildlife, land-scape and historic value of thecountryside.”

National HedgelayingSociety, ‘Way Post’, VinesCross, East Sussex, BN219EG.

Warwickshire’s hedgerows in the spotlight

TRADITIONAL CRAFT


PRODUCTS

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700 litre pillow tanks fromStructure-flex; enabling water tobe carried to inaccessible placeswith no natural supply

The Turkish ForestryCommission has over 1,500small pick-up trucks, which it isplanning to convert into smallfire intervention vehicles.Thesesmall vehicles are able topenetrate forests which largervehicles would find impossible,and will play a vital role incontaining small, localised firesbefore they develop into raginginfernos.To make it viable, eachvehicle needs to carry its ownwater supply, and thanks toStructure-flex Limited, thetransformation from pick-up tofire-fighting vehicle is a simpleone.

Based in North Norfolk,Structure-flex is forging anincreasingly strong reputation

for the manufacture ofinnovative products for thepackaging and transportation ofbulk liquids, both single andmultiple trips; the watercarriers are designed to be re-filled.

Each of the forestrycommission vehicles wouldcarry one of Structure-flex’s700 litre pillow tanks of water,strapped down with a‘bellyband’ harness, for stabilityand safety, and a pump.These

simple additions to a basic pick-up truck make it a self-sufficientvehicle able to carry water toinaccessible places which haveno natural water supply.

“Structure-flex is supplying 6trial tanks and associatedfittings so that the TurkishForestry Commission can carryout trials over the next fewweeks,” says lan Doughty,Managing Director ofStructure-flex.“If the trials aresuccessful, it will open the doorto our flexi-tanks playing a vitalpart in fighting fires invulnerable forestry sites.”

Contact: Ian Doughty,Structure-flex Ltd, 24 GroveLane, Holt, Norfolk, NR256EG. Tel: +44 (0)1263712911 Fax: +44 (0)1263711555 E-mail:[email protected] Website:www.structure-flex.co.uk

Structure-flex provides ‘Water,water everywhere’

PILLOW TANK

Pressure loss indicator fromNordic Tyres shows red iftyre pressure drops by aslittle as 0.14 bar from theinitial setting

CONTACT

Retro-fit seeder unit for use with‘Flatlift’ cultivation systems

To re-think oil seed rapeestablishment, using a Flatliftand cultivation toolbar with theaddition of the new Flatliftseeder unit can dramatically cutestablishment costs, whilstgiving better establishment thanbroadcasting methods.

The new seeder system,consists of two 35 litrepolyethylene seed hoppers withtwo outlets per hopper.Anaccurate, positive displacementfluted metering system ensuresthat the seed is deliveredprecisely through fishtail outletsinto subsoil and cultivated soilimmediately before the packerroller, for optimumconsolidation.

Manufactured for Spaldingsby Horstine Farmery, the

framework is designed forquick and easy fitting to theFlatlift packer roller frame.Drive to the seeder unit isinnovative, taken from thepacker roller shaft which doesaway with the need for aseparate landwheel and allowsseed output to be varied

according to operating speed.The drive mechanism iscontrolled by an in caboperated electromechanicalclutch, which allows quick andeasy disengagement of the driveat headland turns preventingthe wastage of seed.

Working directly behind the

combine harvester on stubbleand chopped straw the systemcan reduce the time and costof establishment.The singlepass, ‘one man’ operation canhelp cure the harvestbottleneck and release men andmachines, that are usually usedfor rape establishment, free forpreparing land for cereals.‘One-pass’ establishment with aFlatlift gives the added benefitsof subsoiling to break the panand improve drainage whichgives stronger, healthier plantswith increased yield potential.

Contact: John Chamberlainat Spaldings (UK) Limited,Sadler Road, Lincoln LN6

Flatlift seeder unit launch

SEED DRILL

CONTACT

27

COMBINE HARVESTER

The CS - harvest quality andquantity in balanceNew Holland has extended itsalready comprehensivecombine harvester offeringwith the addition of two newmodels to its CS range. Theexisting CS540 and CS640have, in a single year, alreadycarved a significant place forthemselves, appealing inparticular to those growersand contractors looking for asound investment in aworkmanlike yet up-to-the-minute machine. This appealnow broadens with theaddition of the five- and six-straw walker CS520 andCS660.

The CS520 offers ‘entry-level’ access to the prestigiousand distinctive new ‘family’styling, first seen on the CXrange, while the 211 kW top-of-the-range CS660, with its8800 litre grain tank capacity,will attract contractors andlarger-scale growers.

Supreme comfort, style andcapacity are the watchwordsfor the entire CS range. Butprobably its most distinguishinghallmark is its ability topreserve the very best-qualitystraw without compromisingoutput, regardless of cropcondition.

“With the gap closingbetween the value of straw andthe value of grain per hectarein a number of situations, andnew markets emerging forstraw, having good ‘baleable’quality is becoming increasinglyimportant,” says productmarketing manager, NigelMackenzie.

It is the CS’ uniquepatented Opti-ThreshTM

system, which allows the rear36° section of the 121° wrapconcave to be folded awayfrom the drum, that isresponsible for this particularaspect of the combineharvester’s performance. The

raise/lower adjustment is madeusing a simple side-mounted,two-position lever. Multi-ThreshTM concave positionadjustment on the rotaryseparator - which is optionalon the existing models, butstandard on the CS660 -complements the thorough butgentle crop treatment.

“In summary, thecombination of features on theCS allows users to set aprecise balance betweencapacity and straw-friendliness,under a broad range ofharvesting conditions and forthe widest variety of crops,”says Mr Mackenzie.

Continuing the strawtheme to the back of themachine, all CS combines canbe equipped with the standardstraw hood canvas, or optionalstraw chopper. “In addition,the top three models can bespecified with an independentchaff spreader which thenallows chaff to be either spreador directed into the straw flowwhen swathing,” says MrMackenzie. “Where straw is tobe incorporated, again there isthe option to spread chaffindependently or in the mainstream of chopped straw,where it will travel further,

especially in side winds.”As for the header, cleaning

ability, unloading rate, thedrivelines and the cab, the CScan be described as ‘best inclass’ in each case. Inparticular, a simple but heavy-duty drum drive, a new cascadepre-cleaning system thatprovides a dual air blast, andTier II-compliant engines allcontribute to an excellent all-round performance.

Automatic headercompensation and stubbleheight control are standard onthe CX-spec headers, withlateral float optional on thefive-straw walker machines andAutofloat an option on all CSmodels.

Visibility onto the headerfrom the quiet andcomfortable Discovery Pluscab is excellent, thanks notleast to the length of the strawelevator. At the same time, themounting position of the slimmonitor on the right-hand sideA-pillar gives the operator at-a-glance eye-level informationon all the important engine,threshing and cleaningfunctions. A multi-functioncontrol lever with large ‘easy-feel’ buttons and in-line gearshift further ease the burden

on the operator.Vital functions are engaged

through electro-pneumatic orhydraulic components - the useof electronics being reservedfor monitoring purposes only.Not only does this avoid thecomplexity of electro-hydraulics, but a pneumaticclutch and actuators alsoprovide very smoothengagement of header,threshing, chopper andunloading system.

A standard air compressornot only provides air pressurefor the remote controls, but isalso invaluable for cleaning themachine away from the yard,particularly when movingbetween seed crops or tryingto reduce contamination byweed seeds.

Practical considerationssuch as this, together witheconomical operation andtechnological advances definethe CS combine harvester’sspecial ability to optimiseperformance and quality ofoutput.


PRODUCTS

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A simple, low-cost tyrepressure loss indicator hasbeen introduced by NordicTyres (UK) Ltd, the distributorof Nokian agricultural, industrialand forestry tyres in the UnitedKingdom and Ireland.

Able to provide an instantvisual warning of a pressureloss as small as 0.14 bar , theindicator is available in versionsto suit most tyres running atany pressure between 1.4 barand 4.8 bar . It is now beingfitted as standard to all Nokiantrailer tyres supplied onwheels, both as originalequipment and asreplacements.

Following inflation of a coldtyre to its recommendedpressure, the indicator isscrewed fully onto the valve inplace of the normal dust cap.Green and red bands within theindicator will then rise untilthey are exactly level.Any lossof pressure will cause the greenband to drop below the red,giving operators a clear visualwarning that the tyre needs to

be inspected for possibledamage, such as a puncture,before being re-inflated to thecorrect pressure.

If the indicator shouldexperience impact for anyreason, it has been designed toshear above the valve ensuringthat there is no loss of air fromthe tyre, allowing movement tocontinue safely until thedamage indicator can bereplaced.

Suitable for tyres fitted to awide range of agricultural,industrial and turf maintenanceequipment, the pressure lossindicator is designed specificallyto prevent the costly andunsafe practice of driving ortowing a vehicle or machineequipped with under-inflatedtyres. Robert Hughes of NordicTyres (UK) Ltd says the devicewill be particularly beneficial onradial tyres where it can oftenbe difficult to tell whetherthere has been loss of pressure.

“Although a radial tyre isbetter able to withstand lowerinflation pressures than one of

cross-plyconstruction,no tyre shouldbe run for anylength of timeat less than itsrecommendedpressure forthe carried loadand the drivingspeed,”commented MrHughes.“Under-inflationis likely toproducesignificantreductions in grip, stability,handling and tyre life. Ourpressure loss indicator shouldprove a very useful aid tomaintaining vehicle safety whilesaving both time and money.”

Priced at £11 (excl.VAT)for a set of four, the NordicTyres’ pressure loss indicator isavailable direct from thecompany and its authoriseddealers.The device will also beexhibited at all forthcomingmajor agricultural shows.

For further informationcontact: Robert Hughes,Sale and MarketingManager, Nordic Tyres (UK)Ltd, Unit 24A, BramptonRoad, Longtown, Cumbria,CA6 5TR. Tel: +44 (0)1228792677 Fax: +44 (0)1228791641 E-mail:[email protected].

New grain sampling spearcan sample up to a 2 mdepth and in five places; incompliance with assuredcrop schemesSpaldings have introduceda new 5 gate aluminiumgrain sampling spear, intotheir comprehensive grainstorage and conditioningproduct range.The new spear is designedto sample grain up to adepth of 2 m and give a

representative sample ofthe grain in five places tohelp comply with assuredcrop schemes.The spear is manufacturedfrom light but durablealuminium, with a pointedend for ease of entry intothe grain.The spear can be orderedfrom Spaldings underproduct number 18050 andis priced at £120.00

Contact: Spaldings (UK)Limited, Sodier Road,Lincoln, LN6 3XJ. Tel: +44(0)1522 500600 Fax: +44(0)1522 689011 E-mail:[email protected]:www.spaldings.co.uk

Tyre pressure loss indicatorcuts costs and improves

TYRE PRESSURE

Pressure loss indicator from Nordic

Tyres shows red if tyre pressure drops

by as little as 0.14 bar from the initial

setting

CROP SAMPLING

CONTACT

CONTACT

Launch of grain sampling spear

29

The change to lead-free sol-ders must take place by July2006 for consumer productssold in Europe.

The new lead-free alloysand the consequent changedprocessing parameters mayhave a fundamental effect onthe reliability of long lifecomponents and systems.To study any long termeffects,TWI are setting up atwo-year international

Group Sponsored Project.The aim of the project is

to develop a clear under-standing of the issues relat-ing to the use of lead-freealloys for long life and highreliability products.Following this understand-ing, the development of test-ing and modelling will pre-dict the influence of thesechanges on product life.

The project builds on

the extensive backgroundexperience of TWI, theUniversity of Greenwich andthe Open University.Results will be availablethroughout the two yearsallowing advance informa-tion to assist companies intheir own implementationstrategies.

Contact: Penny Edmundson,TWI Ltd, Granta Park, GreatAbington, Cambridge CBI6AL. Tel: +44 (0)1223891162 Fax: +44 (0)1223892588 E-mail:[email protected] Website: www.twi.co.uk

ALLOY STRATEGY

CONTACT

RenShape Solutionsproved the answer toa big problem forReko International, ofOntario in Canada,when they won thecontract to produce30 tractor roof proto-types, each weighing40 kg and measuringabout 2 m2.

The size of thepart was further com-plicated by the designwhich included a seriesof large bosses that wouldbe difficult to de-mould.

The parts were pro-duced using Vantico epoxytooling and RenPIMpolyurethanes and wereaccurate and durableenough for functional test-ing.

Reko started the projectby using CAD data to cut aRenShape 450 model. Afibreglass reinforced epoxypaste tool was then builtand used for the mould,while a Shore 50 A siliconerubber was used for the

loose mould inserts.A modified RenPIM

polyurethane system wasused for the prototype partsafter it became apparentthere were no fast settingmaterials readily available,with a pot life long enoughto shoot the part.

After tests, Reko techni-cians realised they could useRenPIM 5218 A/Bpolyurethane for the largeparts, if they used a differentcombination of hardeners.When the hardener wasmixed with RenPIM 5219B,

this slowed the pot life toseven minutes - longenough to mould thesehuge parts.

Two meter/mix dis-pensing machines wereused to shoot the tool,with the first run deter-mining the precise de-mould time. While theseven minute work lifewas adequate, the de-mould time needed to beincreased so an air ejec-tion system was added.

After the mould wasfilled with the specially for-mulated RenPIM material,the prototype remained in itfor several hours. More airejectors were then added tohelp de-moulding and enablethe mould to be openedwhile the prototyperemained in the cavity half.

The resulting partsexhibited good accuracywith virtually no warpingdespite their large size.After inspecting these pro-totypes, Reko’s customerasked for some design

changes to be made and themould was altered to addmore ribs. Some additionalprototypes were cast beforeproceeding to final produc-tion parts that were mould-ed using structural foam.

The resulting partsexhibited good accuracywith virtually no warpingdespite their large size.After inspecting these pro-totypes, Reko’s customerasked for some designchanges to be made and themould was altered to addmore ribs. Some additionalprototypes were cast beforeproceeding to final produc-tion parts that were mould-ed using structural foam.

Contact: Vantico Ltd,Duxford, Cambridge, CB24QA. Tel: +44 (0)1223493000 Fax: +44 (0)1223493002 E-mail:[email protected] Website: www.ren-shape.com

RenPIM produce 40 kg tractor roof prototypesTRACTORS

CONTACT

Lead-free solder in longlife, high reliabilityapplications

Lead-free solder in use; all solders,for European products, must befree from lead by July 2006

ENVIRONMENT - IAgrE

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