With a shared customer base spanning industries such as rail, utilities, and highways, both JSP and Ledlenser understand the challenges faced by those working in some of the harshest and most hazardous environments. From underground confined to nighttime motorway maintenance under heavy traffic, industrial users depend on their PPE to deliver consistent, high-performance protection in every situation. For this reason, we sought independent validation that Ledlenser headtorches would not compromise helmet integrity, performance or compliance.

In this image is Ilir Biba, Saverio Anzelmo, Artur Biba

The company’s key strength lies in the twenty years of experience of its team, which operates across various industrial sectors, including oil & gas, mining, marine, lifting, and testing. Thanks to its strong creative capabilities, the team has, over the years, re-engineered all products available on the market in terms of technology, quality, reliability, and safety, setting itself apart from competitors with innovative and highly effective solutions. The company offers a wide range of products designed for hazardous areas, featuring EX protection (Ex db, Ex h, Ex eb, Ex sb), all tested and certified under both ATEX and IECEx schemes. The explosion-proof slip ring series (EX db) can meet all the power supply needs of machinery, handling currents up to 1200 A, and including digital and analog communication as well as fiber optic transmission. SPM Special Machine’s Ex h-protected cable reels are used in several sectors, such as lifting, mining, port operations, and oil & gas.

In this article, we present the motorized cable reel for hazardous areas, designed for medium-voltage tunnel applications to power a tunnel boring machine (TBM) of approximately 4.5 MW. The protection type is EX h ATEX I M2, and the same design can also be developed according to the IECEx scheme. The special machine consists of a painted steel drum on which a robust and flexible 12/20 kV medium-voltage cable is wound. The system is driven by a motor-gearbox unit, with automatic cable winding and unwinding managed by an electrical control panel. An automatic cable distribution system ensures the perfect positioning of the cable on the drum.

The core component of the motorized cable reel is the slip ring, which is housed inside an EX db enclosure. This particular high-voltage slip ring is designed for harsh environments and is remarkably compact compared to competing products. Its uniqueness lies in the fact that the active parts are not air-insulated but instead encapsulated with a series of insulating materials. Thanks to this design, the system can easily withstand voltages up to 24 kV and currents of about 680 A. The high-voltage slip ring with insulated active parts is a patented innovation by SPM Special Machine, enabling the company to take on new challenges in markets where extreme engineering solutions are required.

SPM Special Machine Srl – Collettori rotanti elettrici e avvolgicavo

Mention COP and the World knows there will be an unusually concentrated focus on the dreaded word ‘climate’ writes Chris Dobson. All eyes and ears for that matter were focused on Belem, Brazil, for the latest COP, the Conference of the Parties organised by the United Nations Framework Convention on Climate Change so that countries can negotiate on how the World responds to the climate crisis.

As I write the educated view is that the World stands at a pivotal crossroad. 2024 saw atmospheric concentrations of carbon dioxide and methane reach new record levels. It was our warmest year on record, exceeding 1.5^oC above pre-industrial levels and there was a large number of extreme events across the globe, including heatwaves, floods, droughts and wildfires.

To be clear the Copernicus Climate Change Service (C3S) and Copernicus Atmosphere Monitoring Service (CAMS) have compiled considerable data that reveals climate and atmospheric signals that have defined this last, decisive, decade.

The data produced by C3S and CAMS for the most recent COP at Belem, acts as both a collective memory of our planet and as an indicator of where our climate could be headed.

This enables governments, industries and communities to make targeted, science-driven choices – from anticipating the impacts of heat extremes and droughts in order to strengthen resilience, to assessing solar and wind intensity to plan renewable energy deployment.

This open-access science-based data ensures that the decisions made in Belém could be grounded in the reality of our planet’s systems - measurable, traceable, and quality-assured.

As Carlo Buontempo, Director of the Copernicus Climate Change Service, says: “A decade after the Paris Agreement, the world is hotter than ever – every year since has ranked among the 10 warmest on record. It’s now evident that the climate is shifting at a pace humanity has never experienced.

“But we do have one superpower in our efforts to tackle climate change – a rich supply of timely scientific data, information and knowledge, all free open and available to everyone without restrictions. It's this information that gives policy makers the power to respond with confidence and clarity in the face of rapid change.

“It is this evidence that must guide the delegates at COP30. The choices we make today will shape the planet’s future, forever. We must ensure those choices are grounded in facts.”

Laurence Rouil, Director of the Copernicus Atmosphere Monitoring Service, says: “From air pollutants to greenhouse gas concentrations, our atmosphere is perhaps the most direct and immediate indicator of every action we take.

“Over the past decade, CO₂ concentrations have risen over 5%, reaching their highest annual levels ever recorded. CAMS monitor their evolution and track their sources. Aside fossil fuel emissions which accounted for almost 75% of total carbon emissions in 2024, wildfires already released more than 1300 megatons of carbon in 2025, and huge amounts of particulate matter that degrades air quality and have harmful impacts on human health.

“This 10-year benchmark is not only a milestone, but also a mirror – that reflects how progress over the last decade measures up to the ambitions of the Paris Agreement. The last decade has seen significant change, and the next decade will be decisive. But knowledge is power; and delegates at COP30 have more knowledge, data and understanding of our atmosphere than ever before – we encourage them to use this to turn ambition into action.”

Florence Rabier, Director General of the European Centre for Medium-Range Weather Forecasts (ECMWF), said: “ECMWF is honoured to participate at COP30 in support of the World Meteorological Organization’s Systematic Observations Financing Facility (SOFF).

“Strengthening global observing systems is essential for building climate resilience and improving the data that underpin our forecasts and climate analyses. By helping countries generate and share higher-quality observations – particularly in regions where data are scarce – SOFF enhances the accuracy of our predictions and the reliability of early warning systems worldwide.

“The forthcoming SOFF Impact Bond will mobilise up to USD 200 million from public, private and philanthropic partners, accelerating investment in these vital observations and ensuring all nations can both contribute to and benefit from a stronger, more inclusive global network. This collaborative effort supports the goals of the Paris Agreement and advances ECMWF’s mission to provide world-leading, data-driven insights that protect lives, livelihoods and our shared environment.”

This is very much a focus on planet Earth. To narrow it down to everyday relevance I turned to a businessman whose business, Hart Industrial Doors, manufactures a wide range of industrial doors, including the highspeed Speedor which, every minute of the working day, is active across the globe.

Chairman, Douglas Hart says “our Brand Speedor is the foremost quality high speed rolling door for industrial and commercial use. We continue to beaver away making doors that reduce energy costs and improve workflow whilst improving internal environments.

“Over the last decades Speedors have been seen everywhere, each one contributing to the prevention of global warming. The concept of automation and speed applications is now widely accepted not only for small doors commonly 8M wide traveling at minimum over 500mm per second. Climate Change is a fact but another vital fact is that industry can mitigate against it.”

With many successful water industry infrastructure projects under its belt, leading industrial lifting equipment supplier Hoist & Winch was once again approached to provide a comprehensive and robustly tested lifting solution for a specialist marine subcontractor. This demanding reservoir application required the transfer of three large-diameter pumping station pipes – each weighing 30 tonnes – across the reservoir waters and up the inclined slope of its dam wall. As always, Hoist & Winch proved up to the task.

This complex hire equipment project required a triple-aspect approach. Firstly, to move each pipe across the water, Hoist & Winch had to supply, install, commission, load-test and LOLER-certify two air-powered chain hoists offering 20-tonne safe working load (SWL). The company proposed a pair of JDN top-hook suspension air hoists, each with its own load chain collector box, air service unit and air supply hoses. The hoist units are each controlled by an individually connected, heavy-duty, air-powered pendant control. They were fixed to the customer’s free-standing fixed gantries on two fabricated floating pontoons (20t SWL), which Hoist & Winch also had to load-test and LOLER-certify.

Secondly, Hoist & Winch was tasked with providing a similar package of services for a large-capacity hydraulic winch system. Here, the company recommended a 12t SWL floor-mounted hydraulic winch with wire rope, diesel-powered hydraulic power unit, joystick control stand and interconnecting hoses. The winch was required to pull each pipe up the inclined slope of the reservoir’s dam wall in conjunction with two rail-mounted travelling gantries (20t SWL) fabricated by the customer.

Lastly, the customer wanted Hoist & Winch to supply four 15t SWL manual chain blocks. The Tiger top-hook suspension type manual chain blocks proposed by Hoist & Winch would support each pipe from the rail-mounted travelling gantries following transfer from the air hoists in readiness for winching up the slope of the dam wall.

Hoist & Winch technical support experts partnered closely with the main contractor’s civil and mechanical engineers throughout this safety-critical project, with strict approval procedures in place.

Load testing of the two air hoists and their supporting gantries was facilitated by a 20t/25t skid-mounted dynamic proof-test load. Working closely with the marine subcontractor’s dive team, the test weights were initially positioned on the reservoir bed.

Dynamic load testing of the hydraulic winch took place in two stages, firstly using an interim site test load comprising lighter concrete components, which also required winching up the reservoir’s dam wall. A further dynamic test was performed on the day of winching the first pipe. This activity was closely monitored to check all aspects of the winching system installation as work proceeded. Indeed, Hoist & Winch was tasked with operating the winch for the full duration of the first pipe lift up the dam wall slope while maintaining constant radio communication with the overall lift supervisor. As the night time closed in the very precise lifting operation had to continue and so the work was completed under floodlights.

Hoist & Winch also provided various other aspects of technical consultancy, including guidance on lifting equipment legislation, lifting operation planning/management, the specification and procurement of a portable diesel-powered compressor, and operator handover training.

“The final outcome was the highly successful movement up the reservoir dam wall of all three pipes in a finely controlled and smooth manner, which delighted both our customer and the end client,” says Hoist & Winch Director Andy Allen. “It’s yet another successful example of how our extensive experience and deep technical knowledge can provide the optimal solution for some of industry’s most challenging lifting and transfer operations.”

Visit www.hoistandwinch.co.uk for further information and to view recent case studies.

 One of the UK’s leading filtration experts has announced the launch of innovative new dust and fume extraction technology from sister company Absolent AB.

Filtermist Limited, which specialises in ensuring the air in workshops is clean and safe to breathe, is now offering the brand-new AD range that maximises ‘True Downflow’ technology to provide dust extraction units which are compact and easy to maintain, yet deliver optimised filtration density.

Designed utilising input from hundreds of real customer use cases, the new offer provides a truly modular, fully ‘customer centric’ product line that is now available to UK manufacturers that undertake abrasive metal processes including welding, laser cutting, grinding and many more, exclusively from Filtermist Limited.

“Several pain points were identified and addressed during the 3-year project,” explained Robert Wiktorén, Absolent Air Care Group’s Chief Product Officer.

“As an existing manufacturer of dust collectors under our Absolent, Dustcheck and Diversitech brands, we knew there was a need in the market for a brand-new way of thinking about dust and fume extraction.

“Traditionally, dust collectors have been sized using generic data to select suitable filter type, filter area and air speeds between filter elements, and resultant footprints have been comparatively large. Noise levels are frequently high due to external compressed air cleaning systems and integral fans, and the units can be difficult to maintain.”

He continued: “When filters need to be changed, even the best current designs require the filter retaining mechanism and moving parts to be in the ’dirty side’ of the unit, exposed to contamination. This is not a great environment for moving parts and requires a tool to reach the filter elements furthest away.

“Our True Downflow combines the verticality of the filter elements with a top to bottom air flow. This unique combination optimises the effect of gravity and ensures that the dust coming out of the filter elements during pulse jet cleaning is forced down to the disposal solution in the hopper.”

The roll-out of the first AD phase includes three models: the 0.5 (which holds two deep pleat cartridges) 1.0 (four filters) and the 1.5 (six deep pleat filter elements). Airflows currently range from 1,200-10,800m³/hr, but can be increased thanks to the modular construction.

The new range is being introduced in stages to customers throughout Europe and the UK, with phase one suitable for use in metal applications such as welding, laser cutting, plasma cutting and non-ATEX abrasive metals (grinding and linishing).

Additional models for use in a wide range of other applications, including explosive dusts requiring ATEX certified equipment and higher air volumes (>65,000m3/hr), will follow later, along with alternative dust disposal options.

Dust collectors suitable for pharmaceutical dust (requiring safe change features) will be added to the range during 2026.

Senior Group Product Manager and former Filtermist employee Andy Darby, who played a pivotal role in developing the new range, went on to add: “A baffle at the inlet evens out the airflow across the volume of the filter and makes sure we use each square metre to its maximum potential. True Downflow is the only solution that guarantees to eliminate any upflow or crossflow with the filter elements - traditionally leading to higher dust retainment and having to oversize the filtration surface.

“This enables us to offer ‘high filtration power density’, meaning we can increase the filter speed and reduce the filter media surface area. Because of this, the solution comes in a far smaller footprint than other filter units on the market.

“Another unique aspect of the new range is the ’CleanChange™’ filter change clamping mechanism. The filter elements are linked together and, as the operator pulls the first element out, the next one is pulled to the front. No tool is needed, and engineers do not have to enter the dust filled unit.

“Locating the fan and cleaning unit inside the body of the extraction unit decreases noise and we can reduce this even further if required by using additional noise attenuating measures. Finally, the standard units will be constructed from pre-treated Galfan steel, which offers a high level of corrosion protection.”

The AD range uses modular construction ensuring extremely competitive lead times, even for customised products.

Robert Wiktorén concluded: “We are confident that the AD range will revolutionise the way end-users, OEMs and systems integrators think about dust and fume extraction.”

Find out more by visiting www.filtermist.co.uk or call Filtermist’s dedicated dust and fume team on 01952 290500.

The digitalization of processes in hazardous areas places high demands on explosion protection. All infrastructure components used in these areas must be intrinsically safe or explosion-proof and certified. The Pepperl+Fuchs Group, a pioneer in the field of mobile devices for hazardous areas, meets these requirements with a comprehensive portfolio of certified solutions, from smartphones, tablets, and HMI systems to intrinsically safe barriers and remote I/O systems to Ethernet APL technology and sensor technology in hazardous areas.

Augmented reality for more efficient workflows

Augmented reality (AR) offers enormous potential at device level for digitalizing processes. With the help of this technology, information can be brought directly into the field of vision and display of employees in real time and presented in a spatially and context-sensitive manner. For example, markings on cables or flanges or process values can be displayed directly next to the corresponding valves.

AR therefore offers particularly great potential for complex tasks such as shutdown work, commissioning, or fault diagnosis in areas that are difficult to access. The technology is also ideal for training and qualifying new employees, for example in practical on-the-job training with AR-supported instructions or via remote support. In addition, AR overlays can be linked to digital twins of assets to simulate scenarios. This integration significantly improves the basis for decision-making, increases efficiency, and ensures safe plant operation.

5G as the basis for AR

The 5G mobile communication standard ideally complements augmented reality technology. In addition to the necessary bandwidth, 5G also provides the low latency required to transmit AR content in real time and integrate it seamlessly. On site, technicians receive context-sensitive instructions, overlay markings on components, and live data such as sensor values or histories directly in their field of vision. At the same time, they can request support or instructions from remote experts at any time, who can be easily connected.

This shifts maintenance processes more toward just-in-time assistance, reducing errors and increasing first-time fix rates. Planning is shifting organizationally toward data- and event-driven workflows, for example, when predictive maintenance alerts automatically trigger AR checklists. An integrative approach is crucial here. AR and 5G are not isolated solutions. They must be seamlessly connected to CMMS/ERP systems, asset digital twins, and role and rights models.

IT security in practice

The high demands placed on IT security require that it be considered from the outset in all digitalization initiatives. Today, this can be easily reconciled with intuitive and efficient operation, for example, using modern, explosion-proof smartphones and tablets from Pepperl+Fuchs. These devices feature integrated biometric authentication methods, such as fingerprint sensors or facial recognition, which ensure fast, user-friendly, and highly secure access.

This eliminates the need for time-consuming entry of complex passwords in everyday industrial use, without compromising security. Biometric identification ensures that only authorized persons have access to sensitive data, control functions, company networks, or applications. Together with encrypted communication and role-based access concepts, this creates a solution that not only successfully bridges the gap between maximum user-friendliness and maximum security but also ensures industrial processes are running smoothly.

Customers also benefit from the fact that Pepperl+Fuchs mobile devices are part of the Android Enterprise Recommended (AER) program. This guarantees consistent, easy deployment and management of mobile solutions through hardware and operating system support, as well as guaranteed security and operating system updates. The Samsung Knox mobile security solution also ensures a high level of device and data security for companies.

Connected workers—highly networked into the future

Intrinsically safe tablets and smartphones already serve as digital and networked hubs for connected workers. They enable authentication, collect sensor data, and bundle a wide variety of communication channels. They also allow for the seamless integration of mobile scanners, IoT gateways, or communication peripherals such as headsets. This makes them a central component for safe, efficient, and networked work processes in hazardous areas.

In the future, platforms for “digital shift operation” will emerge that digitally map handover protocols, know-how transfers, shift handovers, and shift KPIs, thus enabling comprehensive shift digitalization. Step by step, the connected worker is evolving into a highly networked, smart-supported employee who can access and respond to all relevant information, analysis tools, and expert knowledge securely and context-sensitively in real time at any time.

“As a pioneer, Pepperl+Fuchs is continuously working on developing intuitive solutions to optimally connect people in industrial environments, simplify work processes, and sustainably increase efficiency,” says Christopher Limbrunner, Team Lead Product Management of the Enterprise Mobility division at Pepperl+Fuchs. “In addition to providing the right hardware, we also support our customers in the holistic planning and implementation of the necessary infrastructure. They benefit from our many years of expertise and a global support and service network. This ensures that applications are not only compliant and reliable, but also efficient and future oriented.”

https://www.pepperl-fuchs.com

Biomethane from beer and whiskey industry residues

German manufacturer WELTEC BIOPOWER is currently building a biomethane plant for the Irish company Evergreen Agricultural Enterprises Limited. The plant at the company’s headquarters in Monasterevin, County Kildare, will go into operation in mid-2026 after a total construction period of 11 months. The location offers the operator logistical advantages, among other things: “On the one hand, it is well connected to the M7 motorway. In addition, the national gas network for direct biomethane feed-in is in the immediate vicinity,” emphasises Patrick Meade, Managing Director of Evergreen.

No competition with feed production for use of input materials
The €50 million project comprises four digesters and one stainless-steel secondary digester, each with a volume of 4,900 cubic metres. These are mainly used to ferment production residues and by-products from the Irish beer and whiskey industry. The materials are readily available and do not compete with feed production, as they are unsuitable for animal feed. Three additional tanks are used to store liquid substrates. “Despite its size, the plant, with an annual processing capacity of 165,000 tonnes, will be built in just six months of pure construction time. Construction is proceeding according to plan and mechanical completion is scheduled for the end of this year,” says Tobias Gerweler, Managing Director of WELTEC BIOPOWER. “The decision not to use grass silage was a conscious one, so that we would not be competing with the livestock industry,” Patrick Meade continues. A combined heat and power plant (CHP) installed on site generates around 1 megawatt of power for the operation of the plant and supplies heat for the digesters.

Hourly production of 1,300 cubic metres of biomethane
Three rotating long-axis agitators and three submersible motor agitators in the tanks support the effective digestion of the substrate mix. The biogas is collected in the digesters with double-membrane roofs and processed into biomethane using membrane technology. It then enters the public gas grid 20 metres away via the feed-in point. Once commissioned, the plant will produce around 1,300 standard cubic metres of biomethane per hour – equivalent to around 110 GWh of energy per year. The annual output of 65,000 tonnes of digestate is stored in a covered concrete lagoon and delivered to farmers separately as liquid and solid fractions.

By 2030: 5.7 terawatt-hours of biomethane per year
“The fact that German manufacturer WELTEC BIOPOWER was awarded the contract to build the largest plant in Ireland to date was due not only to the technical advantages mentioned above, but also to the short delivery times,” emphasises Managing Director Patrick Meade. This will also enable Ireland to achieve its ambitious expansion targets for biomethane production: the government aims to produce 5.7 terawatt-hours (TWh) of biomethane annually by 2030. To achieve this, existing biogas plants for biomethane processing would have to be expanded, and technically mature plants such as the one built by Evergreen in Kildare would have to be planned and constructed.

www.weltec-biopower.de

As hydrogen plays an expanding role across energy, manufacturing, and industrial sectors, managing safety in its production, storage, and handling presents unique challenges. Hydrogen’s small molecular size allows leaks through tiny openings, while its flames can be nearly invisible and emit low radiant heat, making traditional fire detection methods less effective.

Addressing hydrogen safety calls for a layered approach using multiple detection technologies suited to these conditions. Fast-response ultrasonic sensors detect high-pressure gas leaks at the speed of sound, providing early warning often before a gas cloud becomes visible. Electrochemical and catalytic sensors complement this by detecting lower concentrations of hydrogen or combustible gases where accumulation might occur.

Combined, these technologies provide comprehensive monitoring adapted to different stages and environments within hydrogen applications, helping to reduce risk and improve operational safety.

Products Available for Immediate Dispatch

MSA offers a range of hydrogen-ready detection products, all available for immediate dispatch to support project timelines and operational needs.

Available products include:

• MSA Safety’s ULTIMA® X5000 Gas Monitor: Equipped with MSA XCell® sensors, this smart gas detector supports hydrogen and associated gas monitoring with extended calibration intervals, self-checks (via TruCal®), and a compact design ideal for retrofits.
• MSA Safety’s PrimaX® P Gas Transmitter: Designed for challenging indoor or outdoor environments, this device supports hydrogen and other combustible/toxic gases with easy calibration and durable housing.
• MSA Safety’s SUPREMATouch Controller: A scalable control system capable of managing up to 256 inputs and 512 outputs, ideal for large-scale hydrogen production or processing facilities needing SIL-rated architecture.
• MSA Safety’s SENTRY io®: A modern, wall-mounted controller with touchscreen interface, supporting up to 16 detection points — ideal for smaller hydrogen systems or expansions.

• FieldServer ProtoAir® Gateway: A cloud-connected IIoT gateway for remote monitoring and integration, useful in distributed hydrogen systems or unmanned sites.

These can be tailored to meet the specific safety requirements of your facility, whether in energy, manufacturing, or industrial operations.

Supporting Your Hydrogen Safety Projects

MSA Safety offers a comprehensive portfolio of fixed gas and flame detection solutions developed to address the unique safety challenges of hydrogen applications. Select products and accessories designed for hydrogen environments are in stock and ready for immediate dispatch to help keep your projects on track.

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