Foster Industrial Blog

Foster Industrial is significantly enhancing it's auto darkening welding helmet range with the exciting addition of two new systems. This follows the launch of the base line Foster Pro mask last year & follows product trials and feedback from customers.
The new helmets, the 'Grind-Plus' & the 'Prem-Air' both incorporate brand new True-View welding lens technology. True-View allows the operator to view through the welding filter in it's light state with more clarity & contrast, meaning the operator doesn't have to keep lifting his head top to inspect the job.
As well as True-View, the 'Grind-Plus' head top incorporates a large viewing area of 110 x 60 mm, low battery warning flash, sensitivity & delay function
The Foster 'Prem-Air' marks the companies first venture into the powered air respirator market and carries the requisite high specification associated with any Foster own brand product. The welder's comfort is kept at the optimum level, by a three speed variable air blower & the Prem-Air boasts smartsensor technology which keeps the air flow stable regardless of the variation in load.
With over 150 premium own brand products in the portfolio & a range of TIG wires imminent, the Foster offering goes from strength to strength.

Foster Industrial is to exhibit it's range of welding & plasma cutting equipment at an agricultural show for the eight year running.
Launching Hypertherm's best ever selling plasma cutter the Powermax 45 at the LAMMA show back in 2009, Foster will demonstrate the brand new Powermax 45 XP to the farming sector at the Midlands Machinery Show on November 23 & 24th. The show in it's third year, takes place at the Newark Showground & most importantly is free to enter.
The Powermax 45 XP is likely to take the market by storm, as it is the first cutter of it's kind that can cut metal up to 29 mm on 240 volt power. What is more, simply by changing the torch spares, the cutter allows you to gouge & mark metal too. Customers will be able to view the Foster team putting other Hypertherm machines through their paces too, as the very portable Powermax 30 air, complete with on board compressor, will also be on hand to see. The 30 air severs up to 16 mm metal, runs on 110 or 240 volt power & weighs just under 14 kilos.We're not just displaying plasma cutters either. The must have welding helmet for 2016 has been the Speedglas 9100 xxi, 3M's natural colour lens technology proving a real hit with the punters. We'll have the Speedglas mask on hand to touch, feel & try.

The second in a series of welding & cutting shows to celebrate the company's 130 year anniversary is take place this week. Following on from the incredibly successful welding processes days Foster has embarked on it's most ambitious show yet, with no fewer than four top metal cutting brands demonstrating equipment at the Shepshed HQ.
What chance that Hypertherm would launch the brand new Powermax 45 XP plasma cutter the very same week? They'll be putting the machine through it's paces & with a severance capacity of up to 29mm on single phase power, we're sure it will cause the stir that it's predecessor the Powermax 45 caused at launch.
Dutch plasma profiling manufacturer ACT-Machinery is renowned for it's build quality, innovation & after sales service. With four tables in the range; the Mini, Minor, Maxor & Major, all light to heavy duty cutting applications are covered. ACT are offering live cutting over the two days on their 3 by 1.5 metre demonstration table by appointment.
JEI Solutions are a British company specialising in the manufacture of magnetic drills, bevellers, drilling systems, punching machines & more. They'll bring a high level of excellence & expertise to the show in this sector in their pop up demo area.
Abrasives play an important role in metal cutting and finishing world & our partners Tyrolit are to attend their second Foster show this year. If you're looking to streamline your abrasive processes, save time or improve your finished product their experts will be on hand and have product to try.
The show runs on October 5 & 6th and it's strongly recommend you book first if you want time to see a particular piece of equipment.

Foster is continuing to develop our award-winning team with the appointment of our new storeman Jack Massey.

Jack Massey, our new Storeman

Following a successful year in 2015 and straight off the back of our Welding Awards win, the appointment is the latest in a line of investments demonstrating our commitment to future growth and staff development.

His first role in the industry, Jack was keen to take up the position due to Foster Industrial’s commitment to training and development and the opportunities the position presents for future progression. He said, “One of the things that appealed about the role was the chance to work across various parts of the business and learn about the industry on the job. Even in my interview we talked about how I could progress through the business and having that direction from the beginning was really attractive.”

Richard Foster, Joint Managing Director at Foster Industrial, added, “Our team is vitally important – between then they bring more than 80 years’ experience to the business and play a crucial role in upholding our reputation. Foster Industrial celebrates 130 years in business this year and we wouldn’t be where we are today if it wasn’t for our team. That’s why we prioritise investment in continuous training and development, to ensure that everyone has the latest industry knowledge and the skills that our customers expect.

“Jack’s appointment was in response to growing demand for our services from businesses across the region. Our managed stock service ‘Weldstock’ is proving extremely popular and one of Jack’s key responsibilities is working with our sales team to ensure its smooth operation.”

Foster Industrial, is celebrating its heritage with a look to the future as it hosts two specialist welding events to showcase the technology of the future.

Part of the firm’s 130 year anniversary celebrations, the Specialist Welding Application Days will see representatives from global brands EWM and Miller visit the Shepshed site to showcase equipment, give live demonstrations and take questions.

Featuring the very latest welding techniques and developments, attendees will learn the benefits of new technologies such as TIG SPEED high speed TIG welding, SPOT ARC tack welding and RMD MIG root pipe welding and how they can help improve welding quality and productivity on the factory floor.

Richard Foster, Joint Managing Director at Foster Industrial, explained, “Many of these new technologies are not only faster but also easier for the operator. This has the dual benefit of improving productivity but also helping to address the current shortage of skilled welding operatives.

“We know from listening to our customers across the East Midlands that they want to look at the latest advances in welding equipment and these days are a chance to find out what currently exists and where the industry is heading.”

The events are being held at Foster Industrial’s premises on Golders Road, on Wednesday 6 and Thursday 7 July. Places must be booked in advance by calling Rob Foster on 07977 272966 or Steve Irwin on 07971 0100042.

Purchasing a MIG welder that is suitable for your application and yet fits your budget, without compromising on quality can be a tricky process.

We’ve pulled together a guide of features & pitfalls to look out for when you’re buying a MIG set and put you in know when it comes to terminology & questions to ask the dealer.

FAN ON DEMAND: Lowers running costs and reduces contamination to internal components. The fan kicks in when it’s needed, rather than running all day.

PRINTED CIRCUIT BOARD PROTECTION: If the machine's PCB's are protected from dust & kept away from the fan, reliability will increase. Some manufacturers’ have the parts that need cooling in a duct type housing & the PCB isolated separately.

STEP SETTINGS: If you're looking at step voltage conventional MIG with multiple power settings – “the more the better!”

MIG WIRE INCH BUTTON: A great feature. This will save you wasting your shielding gas when feeding wire through at the start of a new reel.

GAS PURGE BUTTON: Another nice option. Save yourself some MIG wire, when you're setting your gas flow.

BURN BACK: Not all machines have this externally, buy it's good to be able to trim the burn back to the wire according to the application & operator.

SELECTING THE CORRECT AMPERAGE MACHINE: Generally, you should work on 35-40 amps per 1 mm diameter of material to be welded.

DUTY CYCLE: The advertised amperage of the machine offers a headline guide, but the duty cycle of the machine gives up the truth. Light industrial machine duty cycles can be as low as 20%, but more heavy duty MIG's should range between 40-60%. If a 300amp MIG has 30% duty cycle for instance, it's on the edge of acceptability. Duty cycle is determined by how many minutes out of 10, it can weld at 100%.

DUTY CYCLE TESTING: MIGS tested at 20 Degrees & 40 Degrees we consider good.
(Beware any manufacturer who doesn’t quote an ambient temperature for testing)

MANUFACTURERS WARRANTY: Always a great guide to quality. A three year warranty is good.

WELD CHARACTERISTICS: Make sure the arc is smooth & suits your application.
(Some machines are better suited at the low range and others at higher amperage range).

EASY CONTROL PANEL: Simplicity is the key.

DIGITAL METERS FACTORY FITTED: Great to have when you purchase and may be required for calibration requirements. To fit them down the line could be expensive.

DRIVE ROLLERS: Metal rollers are the best. Nylon & plastic ones will always wear away quicker.

DRIVE BLOCK SYSTEMS: Four roll would always be first choice, but some of the lower amperage machines won't have them & two roll therefore would be acceptable.

BOTTLE TROLLEY: If you want a stepped voltage machine to be portable, you'll need one. If you have a full size industrial cylinder check that the running gear & cylinder rack are man enough.

STEPPED VOLTAGE OR SYNERGIC: Synergic MIG's have the edge when you're welding stainless & aluminium as they are pre-programmed, easy to set up & portable. They also provide a better weld characteristic and so give cleaner weld bead with less/no spatter.

INVERTERS: Considerably smaller and lighter and so ideal for site work. All inverters are stepless and so have infinite control. Also cheaper to run power wise.

BUDGET: How much welding are you going to undertake? Gear your purchasing decision around the jobs you will be working on the most.

POLARITY CHANGEOVER; A lot of welders at the light industrial end will to be able weld with gasless flux cored MIG wire. Is the switchover easy on the machine you're considering.

AVAILABILITY OF SPARES/AFTER SERVICE: Ask where the machine is actually made. Even the more recognised brands largely outsource their production, which can lead to quality and after sales issues with lack of continuity of supply for spares.

WHERE TO BUY YOUR MACHINE FROM? Are they a technically sound distributor with good product knowledge? Do they have service engineers who can advise/repair the machine should you have issues?

An overview of Foster Industrial.

Our company history, showroom, technical advice, online purchasing, own brand products, trade counter, industrial gases hub, welding machine repair & demonstration facilities.

At first glance, the number of options when a choosing an auto darkening welding helmet can be a bit overwhelming. Battery or solar powered, viewing area size, weight, lens shade options & adjustment.

What does it all mean - and more importantly, what difference does it really make?

We’ve pulled together a check list to help you select the right helmet:

• Budget: Generally the more you spend, the better the quality of the helmet. How much welding are you doing and how important is to you to have some of the features on offer.
• Amount Of Protection: Are you predominately MIG or TIG welding? You may want a larger head top for added protection in high amperage applications.
• Sidewindows: Do you want peripheral vision or will that distract you from the job in hand?
• Weight: The lighter the better.
• Automatic Park: When you lift the helmet back, will it stay in the upright position?
• Durability: Is it robust enough to withstand fairly severe knocks or high What happens if you drop it? The design should withstand a fall.
• Consumables: Are the inner & outer protection plates readily available & easy to fit?
• Multi Functioning: Thinking about TIG welding or plasma cutting? Then it maybe worth buying a helmet with a filter lens that covers these processes. Typically, shade 5 to 8 is ideal for plasma whilst low amperage TIG welding may require additional sensitivity settings to adjust the arc sensors.
• Grinding Capability: Some helmets incorporate a clear grinding visor underneath the mask. More expensive, but a real time saver and prevents having to have two head tops.
• Build Quality: Will the helmet stand the test of time?
•  Viewing Area: A lot of manufacturer’s offer different sizes. The bigger the better, depending on your budget.
• Battery Life: Most of the higher quality auto darkening helmet filters are powered by replaceable batteries. Be aware that most of the solar powered models only have internal batteries which can’t be removed.
• Headgear: Is it comfortable & more importantly can you re-adjust it when it’s on your head?
• Spectacle Wearer?: Some helmets offer an adjustable rack on the headband to allow more room for the use of spectacles. In some cases, manufacturer’s offer magnification lenses which are relatively easy to fit which eliminate the need for wearing glasses.

Passive vs. Auto-Darkening Lens

Traditional welding helmets have passive lenses – that is they have a fixed shade value. They are worn in the up position to prepare the welding material and then moved downwards immediately before work begins. While they are cost effective, repeatedly lifting and lowering the helmet is inefficient and if the helmet isn't lowered in time there is danger of arc flashes.

An auto-darkening lens does what the name suggests. In its inactive state it has a low shade which is relatively easy to see through. When sensors on the helmet sense an arc start, the lens darkens in a fraction of a second. The helmet stays in position before, during, and after the weld which has the potential to improve weld quality and ease the neck strain associated with snapping the helmet into place.

If you've been following the progress of the Welding World Awards then you’ll understand why there are still a lot of smiling faces around the Foster Industrial offices this week!

The team from Foster Industrial with Rt Hon Michael Portillo, John Wilkinson OBE and the award

Last week, we headed to Birmingham and the glittering Welding World Awards ceremony at the Hilton Metropole, where we were delighted to pick up the award for Best Welding Distributor from The Right Honourable Michael Portillo.

Awarded to the firm that best showed good product knowledge and excellent customer service, the winner was chosen by a panel of industry experts including President of the Association of Welding Distributors (AWD), John Wilkinson OBE, and Adrian Hawkins, Managing Director of Weldability-Sif.

In addition to the award win, we were also named as finalists in two other categories, Best Gas Agent and Best E-Commerce Website Organisation.

All of which has combined to make us very happy! Putting the business up for scrutiny by both our peers and customers was a big decision for us but the results have shown that our confidence in our products and services is not misplaced.

Adrian Hawkins, one of the award judges, commented: “Foster Industrial has established a 130 year history and their longevity is a lasting testimony to the level of service and quality of products they provide to their customers.  They are an entirely appropriate selection for the winner of the "Best Welding Distributor" category awarded by Welding World Awards in 2016. We are delighted that Foster alongside many others have supported our inaugural Welding World Awards programme and we congratulate them for their success in winning this award.”

It’s a huge testament to the commitment of the whole Foster team and makes the work that everyone has done over the last year to build the business and its presence in the region all the more worthwhile.

Now we’ve just got to decide where to put our award!

For further details about the awards visit  http://welding-world.com/

Pelloby Ltd recently worked with Foster Industrial on a project to deliver a bespoke gantry crane for a Siemens AG facility in Port Harcourt, Nigeria.

The 20 Tonne Gantry Crane built by Pelloby

The facility, which is responsible for the overhaul of compressors for the oil and gas industry, required a method of unloading heavy duty equipment from wagons at an external location and then transporting these items into an adjacent warehouse. While this might sound simple enough, the requirement becomes more complex due to the building’s limited height which meant the new crane needed to be able to pass under a low-lying door and then extend to a greater height once outside in order to access the equipment from above.

Our solution was a bespoke travelling telescopic gantry crane, which stood at 5.7 metres when retracted to pass underneath the doorframe, but could extend to just over 7.5 metres in order to unload goods from the wagon. Supporting safe working loads of up to 20 tonnes, the upper crane structure can be raised into position by a rack and pinon system where it is then locked in place before hoisting can begin.

The telescopic gantry crane fully extended

This radio controlled telescopic crane features eight rubber gantry wheels which are housed in special end carriages in order to traverse the workplace. Steering options include circular turning on a point (zero steer), crab steer and true circle four-wheel-steer, while the 4.5 metre span allows the system to comfortably straddle the lorry during the unloading process.

More impressive still is that this system can also negotiate gradients of up to 7°, letting the team at Siemens move the telescopic gantry crane along a sloped surface between the inside of the facility and the loading area. The transition between the flat and angled gradients is accommodated seamlessly thanks to an innovative end carriage system that allows a small degree of articulation in the wheel bogie assemblies.

The heavy duty rope hoist guide system crab is able to traverse the gantry beam at 2-10 m/min speeds, however it must be positioned centrally during ascent or descent of a slope while the crane faces straight on to maintain safe use of the system. Similarly, floor travel speeds must be limited to five m/min while on a slope, while otherwise reaching 10 m/min.

We also fitted additional safety features to the system including four amber flashing beacons to signify to nearby staff when it’s in use and four emergency stop buttons to guarantee operator safety.