number 005. April 2014

INDUSTRY

CONTENTSCARTIF news

Keywords

Talking with…

One of us

CARTIF selection

CARTIF news

Keywords

Talking with…

One of us

CARTIF selection

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published

staff

collaborations

design

photography

CARTIF Research CentreBoecillo Technology Park.

Valladolid, Spainwww.cartif.com

Ana García, María Parcero

Industrial solutions Area. Energy and Environment

Area.

oopscooperative@gmail.com

Pictures: CARTIF, Gullón, SCM, Bossa,

Elsán

REACHING THE FACTORIES OF THE FUTURE

EDITOR’S NOTEIn times of uncertainty like the present, where the production models, financial systems and the level of productivity in each country are questioned, we stop for a moment and reflect on the progress in the industry thanks to technology.

The Industrial Revolution (with its respective stages) and how it has changed the way of life of citizens, helps us analyze the past, present and future of the factories, source of progress and welfare but also sources of energy consumption and pollution. How to maintain high production levels required by the welfare state without diminishing energy reserves and produce more waste than we can manage, are the main challenges for technologists which are working in the field of industry.

The concept of Factories of the Future and projects that are ongoing around them, are the protagonists of this issue of CARTIF NEWSVIEW. We hope you enjoy reading it.

REACHING THE FACTORIES OF THE FUTURE

cartif news

cartif news

This news selection is just a small sample of the Center activities in the last month. You can follow us through our web and social networks.

STEERING COMMITTEE OF THE FP7 LASHARE PROJECT

CHAMBERÍ NEIGHBORHOOD WILL BE THE DEMONSTRATOR AREA OF LIFE EQUINOX PROJECT

This European project brings together in its numerous consortium, six of the

research centers in laser technology better known in Europe and more than

30 companies.

In this case, it is implementing a methodology to measure the state of development of a laser-based system

through a similar indicator TRL.

The aim of the project is to evaluate, in a precise way, a treatment system of application on asphalt paving for the elimination of Nitrogen Oxide (NOX) in the urban environments

The field of action (micro city) is located in the area defined as Madrid Low Emission Zone (LEZ), in the district of Chamberí. The treated surface is approximately, 80,000 m2.

The idea of micro-city has been implemented In order to establish the influence of the product on air quality. The treatment is applied over a large bounded area, minimizing the effects such treatments would have in the environment.

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cartif news

CARTIF PARTICIPATES AS A PARTNER IN THE II CONGRESS OF NEARLY ZERO ENERGY BUILDINGS

The Congress will be held on 6 and 7 May in Madrid (IFEMA) in the framework of the

International Week for Efficient Construction and Renovation SICRE. This is the only event celebrated nationwide to comprehensively address all aspects

that make a building energy efficient, both in new construction and renovation.

The event is aimed at professionals, institutions, and organizations related to the building sector

and energy companies. It is organized by, among others, the Spanish Ministries of Industry, Agriculture and Environment, through the

Spanish Climate Change Office and Economy and Competitiveness.

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THIRD TECHNICAL COMMITTEE MEETING OF OPTIRAIL PROJECT The partners of this FP7 project met in Granada, to pool developments over recent months.

The objective is to develop a new tool based on Fuzzy and Computational Intelligent techniques to manage all the elements that are relevant for track maintenance of railway infrastructure, predicting future conservations needs along the European corridors.

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keywords

keywords

factories of the futureenergy efficiency

sustainabilityindustrial solutions

Factories are one of the responsible of the high quality of life in the XXI century. Any consumer good must be manufactured, including agro-food products that need minimal processing.

The Industrial Revolution allowed the transition from handcrafting to mass production, lowering prices and making available to citizens basic products at first, to improve the quality of life, in a second instance, and 200 years after, unlimited amounts of merely esthetic, fun or luxury objects.

In fact, this process took three iterations. The First Industrial Revolution, which began in the early nineteenth century, had a key pillar: with more efficient steam engines (consuming a tenth of fuel than previous versions) all manufacturing processes became more efficient, cheaper and faster. The production of textiles was

the first sector to took advantage and jump into its mass production.

Just 50 years later, came the Second Industrial Revolution, including new industries such as chemical (oil refining and distribution) and electricity industry (energy producing).

Factories of the Future concept

has been possible by the continuous

development of the manufacturing

technologies

Coalbrookdale by night. Philipp Jakob Loutherbourg. 1801

SCM facilities (Italy)

SCM facilities (Italy)

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Industrial production was already working in mass production (especially on iron and steel components), allowing the start of cars mass production in 1908.

From the early twentieth century, war industry and transport was an incentive for the advancement of manufacturing processes. In the 50s citizens began to benefit from these advances, starting a period of economic prosperity and social welfare that favored the consumption of all types of goods.

In the last years, there has emerged a new concept: the Third Industrial Revolution, promoted by economist Jeremy Rifkin. Energy is the key concept to this third phase: the convergence of Internet and renewable energy, smart networks, integration of renewables, decentralized systems, and factories and buildings acting as suppliers / consumers of energy, represent a new revolution in manufacturing processes.

Factories of the Future concept, which has been made possible by the continuous development of the manufacturing technologies (systems, processes and products) were born here. This is the know-how of CARTIF since its beginnings 20 years ago. At this time, the R&D projects have evolved from the automation and process control of plants to the Fatories of the Future concept, which involves the integration of other concepts such as flexible manufacturing, the effectiveness of manufacturing processes (using energy and raw materials), smart manufacturing processes, robotics and advanced automation.

In summary, curiously, the current trend in addition to energy-efficient manufacturing is SCM facilities (Italy)

Gullón facilities (Spain)

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personalized mass manufacturing. This trend allows on-demand manufacturing and tailored products for the final consumer. It is not a return to handmade products but to a flexible production adapted to the consumer needs.

Among the CARTIF’s industrial research lines, some of them have stand out because of the intimate relation with the “Factories of the Future” concept, such as research lines for integrated management of production that have modernized quality control and have implemented predictive maintenance techniques.

The REEMAIN project, co-funded by the EU through VII PM, is the latest in a series of projects that includes among its aims many of the knowledge acquired in previous projects. The main goal is to design the factory of the future based on energy efficiency and sustainable

management of waste generated during the manufacturing process.

To achieve this, predictive simulation models for production are used to establish new and effective energy management tools. These tools provide information on energy flows , carbon

footprint and its relation to programming and production and supply of the plant.

The technological results obtained will be tested and validated in a Demo Factory of German Fraunhofer IWU Technology Center, later they will be implemented in factories of three different sectors: Gullón, a Spanish manufacturer of biscuits, Bossa, a Turkish textile company and SCM a foundry located in Italy. Thereby, REEMAIN is innovating in resource and energy efficiency with industry sectors (textile and foundry) that were pioneers 200 years ago during the industrial revolution.

Thus, the project aims to achieve a production close to zero waste (Zero Carbon Manufacturing) within energy efficiency 2.0 standards , integrating all the generation, conversion, distribution, control, use, storage and reuse of energy resources necessary for manufacturing.

CARTIF coordinates this project in which 16 companies and organizations from six different countries will develop management tools and models that will help create new standards for the manufacturing of the future. The next step: increasing synergies among factories of the same industrial park to improve efficiency and productivity.

The main goal is to desing the

factory of the future based on

energy efficiency and sustainable

management

Bossa facilities (Turkey)

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Since the beginning of CARTIF, the innovation in process and systems automation has been one of the backbones of their activity. Industry works on the basis that manufacturing may be more or less automated depending on the size of the company and its production level. It isn’t easy to manage properly these processes in an automatically and comprehensive manner. Sometimes, it uses management tools (specific software), and other times, activity is controlled by hand.

Traditionally, manufacturing processes have been running having in mind economic, management and production factors... But that is changing in the last years. Energy efficiency and sustainable management are key issues that many companies have already incorporated in its know-how. The “Factories of the future” concept covers these and other aspects to design and implement every possible innovation on these processes. The REEMAIN project is in line with this topic, one of the most funded by EU.

talking with…REEMAIN Project researchers

The project original idea was born from the common way of work in CARTIF: the exchange of the experiences among researchers of

different fields. In this case, the union of experts in different fields such as manufacturing processes, energy efficiency and integration of renewable had as a result an ambitious idea: integrating the different energy sources in the manufacturing process. Aníbal Reñones, Fredy Vélez and Francisco Morentin are involved in the project team of CARTIF (the team

is made of 14 people in total). They agree in their enthusiasm to see that previous ideas and ongoing research lines adapted

Fredy Vélez. PhD in Energy and Fluid-Mechanical engineering. Energy efficiency and integration of renewable energy.

Innovation in process and

systems automation has been one of the backbones of CARTIF activity

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to the requirements of the European call. Reñones and Morentin contribute with their experience over 15 years in projects related to the industrial diagnosis, monitoring and automation of production, while Vélez contributes his expertise in energy efficiency and integration of renewable in buildings. However, in both cases, REEMAIN represents the first joint action in energy and manufacturing.

Francisco Morentin summarizes that getting an energy optimization wasn’t an important factor for manufacturing at large. Other purely economic aspects (costs of raw materials, logistics and staff) prevailed. But the high price of energy has changed the paradigm. Fredy Vélez is clear: from the moment that the increase in energy makes the final product more expensive and manufacturers have to affect it to the consumer, energy costs go to the fore and the associated solutions to reduce them.

The question at this point is: Are the technologies in the right maturity level to provide these solutions? From the point of view of Aníbal Reñones, the answer is a yes with nuances. The use of renewable energy depends on the geographical location of the facility and climate. The different national regulations are also a factor to consider, remember Francisco Morentin. In Turkey, for example, that is

having a great time the use of these energy sources and the participation in innovative projects is encouraged.

In Spain, the situation has been changing in the last years. Thus the importance of support from the Europeans funds to foster

these research projects which could “scare” some companies, especially when they are testing new technologies that are inmature for the industry.

What remains after four years of hard work in a project like REEMAIN? The answer in this case, is complex. The EC is funding generously innovative investments in other areas of energy

efficiency (such as public and private building) but in the case of industrial prototypes, the conditions are different. The exploitation of the results obtained from the research is one

REEMAIN represents the first joint action in energy and manufacturing

1According to the Community framework for State aid for research, development and innovation (2006/C323/01)

Francisco Morentin. Electronic engineer. Physics degree. Industrial diagnosis.

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of the most important aspects for the EC, but you cannot sell the prototypes created during the project1. In the case of REEMAIN, a very important part of the project is the exploitation of results through partners with interests to market new products, result of the developments of the project. For example, partners like IKERLAN – interested in market batteries- IES -simulation software- SOLERA -solar concentrators-.

We must not forget that in this particular call, we always speak of demonstration projects: the proposed results have to be validated in the real scenarios and not just through a computer simulation. To do this, the solutions emerging in REEMAIN will be tested in the Living Lab or Demo Factory owned by the German technology centre Fraunhofer IWU, in the city of Chemnitz. This demonstrator is unique in Europe and proposes full integration of energy supply

in the production process as a resource to take care of. Thus, manufacturing is considered with an holistic view, and this is precisely the approach that Europe wants to give to this sector.

The companies are an essential part of these projects. Not all have the same motivation

to participate in project consortiums, although the trend is changing. The three researchers agree that Spanish companies are more interested in R&D projects investments because they get a shorter return on investment (ROI).

With regards to the future, Aníbal Reñones would like to take the REEMAIN concept further and launch a project in which the solutions found here will be implemented at industrial park level.

Fredy Vélez agrees and believes the next step is the clustering of factories, so that some use the resources discarded by others and coordinate their energy usage. Francisco Morentin bet to close the circle of production combining the three aspects: optimization of production processes, optimization and integration of renewable energy and integrated management of production (raw materials, energy, staff and logistics), not forgetting that any designed solution must be applied in real factories, and that they need short-term solutions.

The Spanish companies are more interested in R&D

projects investments because they get

a shorter return on investment

Aníbal Reñones. PhD in Industrial Engineering.

Embedded systems for automatic diagnosis and fault

diagnosis.

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one of us

Introduced new concepts and experimental processes own the most advanced chemistry.

While Spain was recovering from civil war, M. Josefa Molera with excellent marks and in just 3 years degree in chemistry from the Central University of Madrid. When she finished it, was as assistant professor at the Chair of Technical Chemistry, directed by Professor Ríus Miró, who offered to do her PhD in laboratories that he led in the field of electro-chemistry, but by the fact of being a woman was rejected by the centre’s director, claiming that “there was no female researcher at the institute.”

Molera waited for the creation of the Institute of Physical Chemistry “Rocasolano” in 1946 to work as an intern in this lab, which in those times did not have many material resources, but nevertheless allowed her doctorate with honors at the Central University of Madrid. Her career was already launched. One year later, she obtained a place of scientific collaboration in college and, to complete their training, she travelled to the Physical Chemistry Laboratory at the University of Oxford where again he found the proper sexist prejudices of that time by the Nobel Laureate Sir Cyril N. Hinshelwood (1956).

In 1951, back in Spain, carried out in the Institute of Physical Chemistry, the research of pyrolysis reactions and low temperature oxidation of organic compounds in the gas phase, and created the Department of Chemical Kinetics which she led until her retirement in 1986.

María Josefa Molera (Isaba (Navarra) 1921 - Madrid 2011)

Molera together with her collaborator Dr. García – Domínguez, promoted and participated in the construction of one of the first gas chromatograph in Spain. The successful project aimed at discovering the gradual transfer of cold flame to the explosion was recognized internationally, incorporating detection of Carbon 14 (14C) into the chromatograph.

In the sixties, Dr. Molera played an important role in the introduction of spectroscopic methods of flash photolysis, while teaching the Research in CSIC (The Spanish National Research Council).

Dr. Molera was one of the few fortunate women scientists who contributed to the reconstruction of the Spanish research system in the second part of the twentieth century.

First gas chromatograph built in the Department of Chemical Kinetics

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cartif selection

In&OutGreat for offices with employees always are in and out. The

aim of this app is the management and improvement of productivity of human resources of a company. In&Out is the app created by Alteda company. The key-concepts of this app are worker absenteeism, the productivity of a project or task

and the costs of absenteeism problem. Thus, this system allows monitoring key labor issues of company’s employees and get the data capture of all situations or key business parameters.

iGo VAMPIRE POWER Calculator

THE THIRD INDUSTRIAL REVOLUTION. Jeremy Rifkin. 2011. Palgrave MacMillan. 19,90$

This app from iGo, allows users to determine how much

wasted energy is being drained from common household

appliances. The app provides a calculator, an energy quiz, energy

conservation information, and an augmented reality marker which cooperates with iGo’s

Vampire Power Awareness web site. The app also directed users

to iGo’s energy efficient power adapters, designed to reduce

and eliminate passive-state energy waste. Available for iOS. The Third Industrial Revolution

is an insider’s account of the next great economic era, including a look into the personalities and players — heads of state, global CEOs, social entrepreneurs, and NGOs — who are pioneering its implementation around the world.

Here, Jeremy Rifkin explores how Internet technology and renewable energy are merging to create a powerful “Third Industrial Revolution.” He asks us to imagine hundreds of millions of people producing their own green energy in their homes, offices, and factories, and sharing it with each other in an “energy internet,” just like we now create and share information online. This trend avoids the dependence on fossil resources.

Two apps to improve management and productivity and a book to understand the advancement of technology in recent years, are our recommendations this month

Available at:

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