Once considered a niche technology, additive processes have now become a proven manufacturing technology, integral to modern production workflows – from prototyping to cost-effective small-batch production across diverse application areas. ALD Vacuum Technologies GmbH, based in Hanau near Frankfurt, Germany, has once again pushed the boundaries of innovation and set a new benchmark with the EBuild® 850. With the world’s largest build volume of 850 x 850 x 1000 mm³, a maximum build rate of 1000 cm³/h, and an electron beam power of 45 kilowatts, it opens new possibilities for manufacturing large, complex components. This not only boosts productivity but also enhances the efficient use of metal powder. Excess material from in-house production or off-spec batches from powder manufacturing can be reused without compromising quality. As a result, the system significantly reduces material costs, ensures efficient powder recycling, and contributes considerably to sustainability in additive manufacturing.

One of the main advantages of additive manufacturing over subtractive methods is its notably lower material consumption and greater flexibility in metal processing. “Rather than removing material, as in milling, components are built layer by layer, with raw material selectively melted using a high-energy source such as a laser or an electron beam,” explains Dr. Alexander Klassen, Vice President of Additive Manufacturing at ALD.

EBuild® 850 – Precise Electron Beam Melting for Powder Beds Up to 15 Tons and 0.01 mm Accuracy

The EBuild® 850 is built around a powerful electron beam source, a movable build chamber, a process chamber equipped with a state-of-the-art powder deposition system, and a separate extraction unit for powder preparation and component removal. To enhance production capacity, a second build chamber can be integrated: while the melting and cooling process occurs in one chamber, the other can be used for component removal and preparation of new build jobs. “In order to deliberately overcome the limitations of component size, we expanded the chamber design significantly – without compromising process stability,” explains Dr. Klassen. The high-precision withdrawal unit positions the powder bed, which can weigh up to 15 tons, with a repeatability of approximately 0.01 mm across the entire build height of 1000 mm. The material supply and powder deposition are managed by a specially developed system designed to reliably process even poorly flowing powders. To prevent unwanted temperature effects on the material, the system features an efficient water-cooling system. The development of the EBuild® 850 greatly benefited from ALD Group’s technological expertise in vacuum technology, high-temperature processes, and the precise movement of large masses. As the powder is deposited layer by layer by the powder application system, the electron beam precisely follows the predefined contour, fusing the material with high accuracy. To minimize heat loss and optimize energy usage, all chamber walls and thermally stressed components are equipped with heat shields. Like all movable components and sensors, the powder-handling valves are designed with enhanced thermal resilience, ensuring reliable operation over extended periods, even at elevated temperatures and under the influence of metal dust.

World’s Largest PBF-EB System Combines XXL Build Volume and High-Temperature Materials

With the EBuild® 850 – featuring a build volume of 850 x 850 x 1000 mm³ and a build rate of 1000 cm³/h – ALD has developed the world’s largest PBF-EB system (Electron Beam Powder Bed Fusion). This marks a decisive step towards meeting the unique requirements for manufacturing large, complex metal components within an industrially scalable solution. One of the system’s core advantages is its 45 kW electron beam, the highest beam power worldwide for PBF-EB systems. The inertia-free magnetic optics allow the electron beam to be deflected over 100 times faster than conventional systems. This high deflection dynamic enables the beam to move faster than the thermal inertia of the powder material, allowing multiple build zones to be processed simultaneously with a single beam source without affecting the melt or material quality. As a result, the EBuild® 850 offers a melting rate potential more than ten times greater than that of conventional laser systems. “This not only translates into significantly increased productivity for our customers while maintaining consistent quality, but also opens entirely new possibilities for alternative processing strategies and faster throughput,” says Dr. Klassen. Another key advantage lies in the system’s considerably higher process temperatures, ranging from 700 to 1200 °C, which also allow the processing of high-temperature-resistant materials. Titanium alloys such as Ti64, nickel-based alloys, or titanium aluminides – commonly used across various applications – can be reliably processed with ALD’s technology. Residual stresses, which can cause distortion or deformation, are minimized thanks to the high process temperatures – a critical quality factor, especially for material-sensitive components or complex geometries. Another benefit for users is the system’s separate extraction unit outside the main process chamber. Optionally, a second build chamber can be installed. This allows the next build job to be set up in parallel with ongoing production, significantly increasing overall productivity. Unproductive downtime is virtually eliminated, resulting in a noticeable boost in production output. In addition to efficiency gains, integrated process monitoring contributes to quality assurance. The EBuild® 850 uses the electron beam not only to build the components but also as an analysis tool. Each individual layer is monitored in real time, following a principle similar to that of a scanning electron microscope. This allows defects to be detected as they occur, enabling immediate adjustments to the process. Ideally, this reduces or even eliminates the need for subsequent inspection procedures, further enhancing process reliability and component quality.

From Cost-Intensive Material Use to Resource-Efficient Production

A central challenge lies in the efficient handling of metal powder – particularly when it involves recycled or off-spec material from the powder manufacturer. The EBuild® 850 opens up new possibilities: its high power of 45 kW, innovative process control, and ability to melt very thick layers enable the production of components using a significantly broader particle size distribution. Other systems require narrow particle size ranges, which initially produce larger amounts of residual material. The EBuild® 850’s broader particle size tolerance makes the process especially economical. A key benefit is the ability to reuse excess powder from in-house processes, which can be deliberately reintroduced into the production cycle. Additionally, off-spec batches from the powder manufacturer can be incorporated without compromising component quality. The high process temperature ensures stable processing, even when powder batches are inhomogeneous. This not only makes material usage more efficient and cost-effective, but also establishes a sustainable recycling process that minimizes material losses and strengthens the circular economy. With the EBuild® 850, residual material is transformed into new production value, designed to be resource-efficient, economical, and forward-looking.

Further information is available at www.ald-vt.com

EXAIR’s Chip Trapper provides a fast, efficient way to remove solids such as chips, swarf, or shavings from used coolants or other liquids, prolonging their useful life. EXAIR now offers a new Chip Trapper Lid Rebuild Kit to bolster performance on older units and help maintain optimal efficiency. By replacing a few key components on the Chip Trapper system, an older unit can be restored to like-new condition with minimal effort.

Chip Trappers are pneumatic vacuums; thus, they have no moving parts to wear out over time and provide a long-lasting solution for any process. However, over time, performance may degrade due to worn sealing rings, or prolonged chemical reaction between the sealing gaskets and sump coolant. EXAIR’s Chip Trapper Lid Rebuild Kit comes with replacement bulkhead, quick connect, and sealing gaskets to replace faulty or worn-down seals that may limit the Chip Trappers performance. Also included is a detailed instruction label outlining how to properly utilize the Chip Trapper valves.

Preventive maintenance is an effective way to keep products operating at optimal levels. The Chip Trapper Lid Rebuild Kit comes in versions for our 30, 55, and 110-gallon Chip Trappers. In addition to the Chip Trapper Lid Rebuild Kit, EXAIR offers a variety of rebuild kits for Chip Trapper Valves, Atomizing Nozzles, Filter Separators, and more. Rebuild Kits for the Chip Trapper Lid begin at $81.50. https://exair.co/190-ctrrbk

For more information contact:            
11510 Goldcoast Dr.
Cincinnati, OH  45249-1621
Phone: (800) 903-9247
E-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

To achieve reliability and operational efficiency, organisations must assess the tools used to manage maintenance. A key decision is whether to rely on a homegrown system or invest in a purpose-built Computerised Maintenance Management System (CMMS).

Homegrown solutions can seem attractive, familiar, low cost, and easy to control. However, these benefits often fade as the organisation grows. A professional CMMS is designed for complex, large-scale asset environments and supports proactive, data-driven maintenance.

Here are five reasons to move beyond in-house systems.

1. Scalability and Adaptability

Homegrown systems often begin as spreadsheets or small databases. They may work initially but rarely scale. As assets or sites increase, these systems become unstable, difficult to modify, and reliant on a few individuals.

Adding locations, integrating equipment, or producing centralised reports soon becomes impractical. A short-term fix becomes a long-term obstacle.

Modern CMMS platforms such as PEMAC ASSETS support growth through open APIs, cloud infrastructure, mobile apps, and integration with IoT sensors and ERPs. They evolve with your organisation.

2. Data Integrity and Insights

Good maintenance depends on clean, consistent data. In-house systems often suffer from manual errors, inconsistent naming, and scattered information. This makes accurate reporting, such as MTBF or PM compliance, extremely difficult.

A CMMS enforces standardisation and consolidates data into one reliable source. Over time, organisations gain clear insights into performance, labour productivity, inventory accuracy, and failure trends, enabling proactive decisions.

3. Integrated Functionality

Homegrown tools usually cover only basic tasks. A CMMS manages the full asset lifecycle, including:

• Work order histories
• Parts and supplier data
• Technical documentation
• Cost trackingCondition-based monitoring

• Mobile access allows technicians to update jobs in real time, improving accuracy and productivity. Professional systems also integrate with inventory, procurement, and planning tools, a capability most in-house solutions lack.

  4. True Cost of Ownership

  Although in-house systems may appear cheaper, hidden costs accumulate, including development time, fixes, and limited support.

  Every hour spent maintaining an internal system is time not spent improving operations. CMMS vendors continually refine their platforms. With PEMAC ASSETS, organisations gain predictable costs that include hosting, updates, backups, and support.

  5. Security, Compliance, and Risk Reduction

  Cybersecurity threats and regulations require secure, auditable records. Homegrown tools often lack encryption, access controls, backups, and audit trails.

  Professional CMMS platforms provide secure storage, disaster recovery, controlled access, and full activity logs, supporting compliance with standards such as ISO 55000 and 21 CFR Part 11.

  Conclusion

  Choosing a professional CMMS is a strategic step towards maintenance maturity. Homegrown systems restrict scalability, visibility, and improvement. A purpose-built solution such as PEMAC ASSETS enables organisations to scale confidently, improve data quality, strengthen preventive strategies, enhance productivity, and meet compliance requirements.

  www.pemac.com

A Borger Rotary Lobe Pump has completed more than 20 years of service for a food manufacturer that produces syrups, concentrate, vitamin combinations and emulsions for a range of alcohol-free beverages.

Recording over two decades of reliability with very low wear, and still going strong, the Borger pump is managed by a control unit (combined with a frequency converter) that regulates speed, so that the liquid sugar is transferred out of the storage tank into the mixing tank in doses.

In a system that also sees varying levels of liquid sugar added to the process to suit each type of drink, the Borger Rotary Lobe Pump, with its Maintenance-In-Place design, has kept service time and costs to a minimum.

Borger already has considerable experience in similar installations, including at a sugar refinery, where its pumps handle white mass (sugar syrup with crystals). These proven units manage a highly viscous solution (around 50% solids) during the final processing stage, where syrup is spun to produce fine white sugar crystals.

I’m thrilled to announce that Ultimo picked up the prestigious Innovation Impact Award at the International Maintenance Conference (IMC) gala ceremony last week. This recognition reflects our relentless commitment to transforming enterprise asset management (EAM) through innovation.

IMC provides a fresh, positive community-based curated experience to gain knowledge and perspective for advancing reliability and asset management through people, their managers, the processes, the data and the technology. The awards are presented during the event, where the most prestigious firms and most awarded asset management professionals in the world are in attendance.

AI-Augmented EAM: Pioneering the Future of Asset Management

Ultimo’s artificial intelligence (AI)-augmented EAM platform represents a bold leap forward in asset management technology, redefining how organizations manage maintenance, operations, and asset lifecycles. With our award-winning Agentic AI strategy, Ultimo delivers intelligent, actionable insights that have already transformed operations for over 2,500 industrial organizations worldwide.

Digital Coworkers and Agentic AI

In July 2025, Ultimo introduced its first agentic AI use case focused on environmental, health, and safety (EHS) incident reporting. This “digital coworker” operates as an expert embedded within organizational workflows, continuously monitoring work requests to autonomously capture incidents, near-misses, and unsafe conditions that might otherwise go undocumented.

By automatically generating detailed reports - including event descriptions, damage assessments, and injury details - the system provides unprecedented visibility into workplace safety risks for EHS officers, enabling proactive risk mitigation and regulatory compliance. This technology exemplifies Ultimo’s broader agentic strategy, where AI augments human teams, predicts maintenance needs, prevents failures, and balances uptime with costs.

Digital labor isn’t just an incremental improvement - it’s a fundamental transformation.

Ultimo’s AI-augmented EAM is also tackling maintenance downtime. It’s estimated that 80 percent of mean time to repair (MTTR) is spent diagnosing problems, often slowed by incomplete failure reports and communication gaps. Ultimo dramatically reduces this wasted time, directly impacting the bottom line. In manufacturing alone, unplanned downtime can exceed $100,000 per hour. By improving diagnostic speed, organizations not only reduce costs but also enhance productivity, employee satisfaction, and overall asset reliability.

Ultimo’s intuitive AI capabilities empower frontline employees to create accurate, comprehensive failure reports with minimal effort. By capturing all sensory observations - what they see, hear, smell, and feel - Ultimo ensures maintenance teams receive the complete picture needed for rapid troubleshooting. This approach accelerates issue resolution, increases asset availability, and frees skilled staff to spend more time on hands-on work, rather than administrative tasks.

The platform also enhances user experience with AI-augmented features such as photo-based meter readings, auto-generated image and document captions, and auto-translated multilingual data. The result is reduced admin time, improved collaboration, and consistently higher data quality across the organization.

Industry-First EAM Maturity Model and Circle of Collaboration

Ultimo has also pioneered the industry’s first EAM Maturity Model, offering a clear roadmap from reactive maintenance to fully autonomous asset ecosystems. The model identifies five stages of EAM evolution, helping organizations benchmark performance, plan their transformation, and maximize operational value.

Complementing this, our Circle of Collaboration framework ensures seamless communication across departments, breaking down silos and aligning teams around a single source of truth. By connecting maintenance, operations, safety, and reliability personnel, organizations achieve faster deployment times, enhanced coordination, and sustained operational improvements.

Proven Global Impact

Supporting over 134,000 active monthly users, Ultimo’s platform demonstrates reliability, scalability, and measurable value. Our record of zero major support escalations highlights the platform’s dependability, while our rapid deployment and time-to-value set a new standard in enterprise software.

Strategic partnerships and industry recognition further validate our innovation leadership. Collaborations with industry leaders such as ABS Consulting and TwinThread ensure our AI solutions address real-world challenges, while awards like the Innovation Impact Award underscore our commitment to shaping the future of asset management.

Delivering Measurable Benefits

Ultimo’s AI-augmented EAM platform delivers tangible advantages, including:

• Preventing unexpected disruptions and significantly extending asset lifecycles
• Reducing data silos and improving collaboration for efficient work
• Enhancing asset utilization while reducing operational costs and improving uptime

Looking Ahead

Ultimo continues to lead the industry by expanding agentic AI capabilities, driving autonomous operations, and empowering organizations to predict, prevent, and optimize maintenance at unprecedented levels. Our vision extends to self-diagnosing and self-optimizing assets, creating the foundation for the next generation of enterprise asset management.

Being awarded the Innovation Impact Award is more than a personal achievement - it’s a recognition of Ultimo’s ongoing mission: to transform asset management, drive operational excellence, and redefine what’s possible for organizations around the globe.

Read more about our agentic AI approach here.

Like the VSRT, Fulton’s VSRT-E hybrid boiler is a revolutionary innovation in steam boilers, combining cutting-edge design with sustainability to redefine efficiency in the sector.

The ultra-low NOx, high-efficiency VSRT-E seamlessly integrates a traditional gas-fired system (inc. Hydrogen blend) with electric steam raising capability, allowing operators to optimise energy use, reduce emissions, and offers an alternative to traditional dual fuel solutions.

Engineered for easy installation and operation, the VSRT-E features an intuitive control system and compact footprint. With thermal efficiencies of 82.5% (Gas) and 99% (Electric) and a steam dryness of 99.75%, it significantly lowers fuel consumption and operating costs.

Its hybrid capability enables users to switch between gas and electricity, balancing energy sources to minimise carbon impact and take advantage of off-peak tariffs, further enhancing cost-effectiveness. By reducing CO₂ emissions and promoting cleaner energy use, the VSRT-E actively supports national decarbonisation goals.

Designed with safety in mind, the VSRT-E incorporates advanced monitoring and diagnostic features, reducing operating risks whilst ensuring reliable performance. Its unique design reduces maintenance requirements, minimising breakdowns, and downtime.

As the industry navigates towards a sustainable future, the VSRT-E sets a new benchmark in innovation, offering efficiency, reliability, and environmental responsibility in a single, future-proof solution.

And talking of the future, Fulton plans to expand the VSRT-E range with 100HP (1,000kW) and 125HP (1,200kW) models, responding to industrial users requiring higher steam outputs. These additions will complement the 60HP (600kW) model currently available in the UK, creating a comprehensive portfolio for commercial and light industrial applications.

The company is also exploring advanced control integrations, including AI-driven load prediction algorithms and blockchain-enabled energy trading compatibility, developments aiming to position the VSRT-E as a grid-interactive asset capable of autonomously optimising fuel selection based on real-time carbon intensity data and energy market signals.

www.fulton.co.uk

Hart Door System’s wind-resistant, high-speed, industrial rolling door, Speedor Storm, is ready for business be it a factory, warehouse, storage facility or any kind of plant operation writes Chris Dobson.

The ability to withstand substantial wind pressure with wind resistance available up to ‘wind class 5’, as defined by DIN EN 12424, in the closed position this high-speed door is ready for openings to a maximum 8 metres width or height subject to 48 square metres.

Major entrances open/close automatically so avoiding the escape of expensively heated air into the environment.

Speedor Storm helps industry specifically by;

·         Aiding productivity – because entering and leaving a building can be done more rapidly.

·         Helping to create a better working environment through its high-speed operation which means there are no unnecessary open periods.

·         By saving on the substantial cost of heating.

Designed and made in the UK at Hart’s Newcastle upon Tyne headquarters from where its teams of engineers are available throughout the UK for installation of Speedor Storms and subsequent servicing and maintenance thereafter.

Speedor Storm’s strength and wind resistance comes from its multi-layer PVC and textile, both long-lasting and tear-resistant and its inbuilt horizontal curtain braces and no external cumbersome and noisy external wind bars.

There is a colour choice as well as ‘a with or without vision panel ’ which combine to deliver a good appearance, operational effectiveness and a performance product.

Safety features are of course paramount, and here they include a state of the art safety light curtain, anti-fall protection and sensors to activate the door, all compliant to the Health and safety standards. There is a range of operating methods that include hands free sensors, floor induction loops, radar, photo beam, radio operation, movement and presence sensors, handheld or vehicle-mounted radio transmitters,  or simple push button and or pull cords.

The automatic operation can be set to include or exclude pedestrians as desired. If warning lights or klaxons are required, these can be incorporated in a complete door system and control panel which are designed for any conceivable need including integration into a Building Management System if necessary. This is delivered via its unique guide system in combination with other carefully designed features.

www.hartdoors.com