Burton-based Doncasters, has acquired Uni-Pol, a global business specialising in the manufacture of superalloy cast parts. This acquisition places Doncasters amongst the largest manufacturers of high-precision alloy components in the global supply chain, enhancing the future for the group, its employees, and customers. The precision parts market is expected to reach revenues of $300 billion by 2025, growing at a CAGR of over 10 per cent between 2019 and 2025. Doncasters has seen the industry develop since 1778, when the company’s founder, Daniel Doncaster applied the crucible steel-making process to the manufacture of hand tools. Since it was established, Doncasters has grown to be an international manufacturer of high-precision engineering components. Each of its eleven advanced production facilities across Europe and the US has specialist capabilities and serves a broad blue-chip client base, including Siemens, GE, Rolls-Royce, Ansaldo, BorgWarner, Garrett Motion and Cummins. Established in 2005, Uni-Pol has four manufacturing facilities in China, India, Mexico and the UK. This acquisition means that Doncasters will have an annual revenue of over $500 million and employ nearly 3,000 people across 7 countries. “Some time ago, we identified Uni-Pol as a natural fit with the Doncasters group of businesses,” explained Mike Quinn, CEO of Doncasters. “The additional support from the group gives Uni-Pol extensive opportunities to further develop its offering and, in turn, Doncasters will benefit from Uni-Pol’s additional expertise and technology. “It also broadens Doncasters’ product offering, benefiting existing and new international customers, particularly those in Asia and South America. “This is an exciting time for the Doncasters group of businesses, as we invest in upgrading our operating equipment, technology platforms and capabilities, so that we can be more efficient, accurate, timely and can compete on a wider scale. We’ll also be strengthening and developing our talent, who will benefit from the opportunities created by this acquisition,” concluded Quinn. David Orr, Chief Executive Officer of Uni-Pol, said: “This is a fantastic new chapter in our history. This synergy is great for our people and for our customers as we focus on supplying complex, high-quality competitive products for the automotive and aerospace industries on an international scale. I’m looking forward to working together as one team, towards what looks like a bright future for us all.”

Carlsberg has been fined £3 million after a contractor died and another was seriously injured following an ammonia gas leak at one of its breweries. The incident happened at Carlsberg’s site in Northampton. An investigation by the Health and Safety Executive (HSE) found Carlsberg hadn’t put proper controls in place. David Chandler, 45, was killed and David Beak, now 57, was seriously injured. David Chandler was a father of two, from Bridge North, Shropshire. His family said they welcomed the end of the case against Carlsberg and hoped no other families would have to suffer as they have. Birmingham Crown Court heard that at its Northampton brewery Carlsberg had failed to put in place appropriate isolation controls to prevent exposure to ammonia before work started to remove a compressor from a refrigeration system. The Principal Contractor for the project was Crowley Carbon UK Ltd, which had appointed numerous contractors to assist in the works. On 9 November 2016 while the compressor was being removed, there was a large, uncontrolled release of ammonia. David Chandler and David Beak were both employees of sub-contractor Speedrite NE Ltd. Twenty people needed hospital checks after showing symptoms of ammonia exposure. It was several days before the leak was contained and gas levels dropped to a safe level. David Beak, of Failsworth in Oldham, was seriously injured. Carlsberg Supply Company UK Ltd, who were summonsed under their new company name of Carlsberg Marston’s Brewing Company, pleaded guilty to charges under Section 2(1) and Section 3(1) of the Health and Safety at Work etc. Act 1974, and Regulation 3(1) of the Management of Health and Safety at Work Regulations 1999. The company was fined £3 million with costs of £90,000. Mr Chandler’s family, in a statement, said: “We welcome the conclusion of the prosecution case against Carlsberg UK Supply Company Ltd following the death of David five and half years ago. “As a family we will never fully accept the death of David in such tragic but preventable circumstances and the legal process involved has been emotionally exhausting as well as frustrating given the length of time which has lapsed since the accident. “We are pleased that improvements have been made at Carlsberg’s site in Northampton which will hopefully ensure no other families suffer the anguish we have endured since November 2016 when the failings at the brewery resulted in the deadly release of ammonia gas which caused David’s death. “David was a loving husband, adoring Daddy and much-loved brother and Uncle. We are devastated that his young family will not be able to share their lives with him as they grow. He was a larger-than-life character whose loss has left a massive void nothing can replace. “There have already been so many special and precious moments which David has missed out on and the fact that there will continue to be some many more as his daughters grow into young ladies breaks all our hearts daily. He is missed every day, and our lives will not ever be the same without him.” HSE principal inspector Samantha Wells said: “Industry guidance on safe isolation of plant should have been followed. This would have ensured that a higher level of isolation was in place, for prevention of exposure to this highly toxic and flammable substance. “Both the client, Carlsberg, and the Principal Contractor should have worked together to ensure that the risk was adequately managed. Not only Carlsberg had a duty here. There was also a very clear duty on the Principal Contractor. “This underlines the dangers of not following industry guidance when working with toxic and flammable substances – HSE will take action against all who fail to ensure the safety of employees and others who may be exposed to danger. “Projects involving multiple contractors require effective management arrangements, so it’s clear who is responsible for every part of the work and that safety checks are carried out before allowing work to start.” The Health and Safety Executive also brought a case against Crowley Carbon Ltd in relation to the incident which led to the death of Mr Chandler and the injuries to Mr Beak, which were also due to be tried but for the company being placed into compulsory administration by creditors.

Rolls-Royce is entering the hydrogen production market and acquiring a 54% majority stake in electrolysis stack specialist Hoeller Electrolyzer, whose innovative technology will form the basis of a new range of mtu electrolyzer products from its Power Systems division. Hoeller Electrolyzer, based in Wismar, Germany, is an early-stage technology company that is developing highly efficient polymer electrolyte membrane (PEM) stacks, under the brand name Prometheus, for the cost-effective production of hydrogen. Hydrogen is an increasingly attractive power source to fuel the green energy transition and demand for ‘green’ hydrogen – whose production creates no CO2 – is expected to rise significantly. It is needed for fuel cells and hydrogen engines, for the production of synthetic ‘drop-in’ fuels and for industrial processes that currently use hydrogen that is not created in a carbon neutral process. Consequently, high-performance electrolyzers are a key component of any hydrogen system. Dr. Otto Preiss, COO and chief technology officer, Rolls-Royce Power Systems, said: “By developing our own mtu electrolyzers and by taking a majority stake in Hoeller Electrolyzers, we are methodically growing our hydrogen portfolio and securing access to this fascinating technology, which is not a pipe dream but has great market potential. “This will enable us to supply complete hydrogen solutions and make a significant contribution to protecting the climate. Our complete hydrogen solutions will enable customers to store renewably produced energy in the form of hydrogen for use as and when required, or for further processing or onward sale.” In hydrogen electrolysis, water is subjected to DC electrical current, producing hydrogen at the negative pole and oxygen at the positive pole. In this way, it is possible to produce carbon-neutral hydrogen by using electricity from renewable sources such as solar or wind. The electrochemical reaction takes place in a cell between plate-shaped electrodes separated by membranes. Hundreds of cells located one above the other and pressed together form a ‘stack’, the heart of an electrolyzer. Founded in 2016, Hoeller Electrolyzer has positioned itself, with Prometheus, as one of the few highly specialized expert players in the field of high-efficiency PEM electrolysis stacks. Its founder, Stefan Höller, has more than a quarter of a century’s experience of developing electrolysis technology and has already registered 14 patents connected with Prometheus. Particularly high efficiency is promised by special surface technologies for the bipolar plates which significantly reduce the use of expensive precious metals platinum and iridium as catalysts, as well as increased output pressure. Stefan Höller, Managing Director, Hoeller Electrolyzer, said: “Our stack is going to produce hydrogen at a price not previously thought possible.” Rolls-Royce and Hoeller Electrolyzer say they are united by a shared belief in the opportunity of zero-carbon energy – both for power supply and the propulsion of heavy vehicles. With decades of experience and systems expertise, Rolls-Royce is going to develop a complete electrolyzer system and has a global sales and service network, which opens up the potential for significant worldwide sales. Matthias Kramer, CFO and joint Managing Director, Hoeller Electrolyzer, said: “In Rolls-Royce, not only have we found an important customer for our stacks, we’ve also secured an ideal partner and supporter who shares our vision of putting stacks into full production.” Development work on the first mtu electrolyzer using a stack from Hoeller Electrolyzer is already underway. The equity in Hoeller Electrolyzer now held by Rolls-Royce comes from departing minority shareholders and from an increase in share capital. Financial details of the transaction are not being disclosed. Stefan Höller and Matthias Kramer will continue to lead Hoeller Electrolyzer as a standalone company, with the goal of building a leading international stack manufacturer.