Burning Ambition
Ian Harbison spoke to Andrew Barnett, second generation Managing Director of Barnbrook Systems.
IH: Tell us a bit about Barnbrook Systems.
AB: It was founded by my father 50 years ago and now has about 50 staff. It works across aerospace, defence and transportation, with a focus on safety, reliability and innovation. We are able to design, engineer, prototype, and qualify in house to produce our own products and engineering solutions. At the same time, the company has a long history of overhauling out of production items by other companies. With numerous certifications, it is, unusually for an SME, working directly with major manufacturers and suppliers.
IH: You recently made an appearance on prime time BBC television?
AB: Yes! The One Show asked us to demonstrate E:BAG. This a joint development with Flair, combining their fire suppression bags with our BlueCube remote sensing and monitoring technology. We are aiming it at the airline market as a way of dealing with the increasing threat from lithium ion battery incidents. Cabin crew can simply drop mobile phones, laptops or e-cigarettes into the E:BAG then close it, the temperature sensitive smart fabric then extinguishes flames or prevents ignition. BlueCube monitors the temperature to show when the danger is over.
IH: Has it generated much interest?
AB: Yes, but it also attracted interest when we launched it at Farnborough, and we are now in serious discussions with Emirates, IAG, Qantas and Qatar Airways, as well as the Boeing Safety Board.
And airports such as Gatwick, Heathrow and Manchester are also viewing this as a solution, as they have regular problems with discarded e-cigarettes or items in passengers’ carry-on bags catching fire.
An unexpected customer for us is TJ Waste and Recycling’s Materials Recovery Facility which is close to us in Portsmouth. The facility burned down last year after a major blaze that might have been caused by a battery. They will use E:BAG technology to isolate any suspect items when they are sorting through rubbish.
IH: Any other aerospace applications for BlueCube?
AB: It is being used in Leonardo helicopters for air-to-air and helideck refuelling, to confirm that there is a secure connection and transfer can safely start. There have been three contract awards and we have now delivered around 300 devices.
We also have a modified version called BlueDot, which is being adopted by Protium, a producer of green hydrogen, to enable the safe storage, use and transportation of green hydrogen systems, for airborne and non-airborne applications. Perhaps the best opportunity is hydrogen-powered airside vehicles. If every vehicle is electric, you probably haven’t the charging infrastructure to cope.
However, at the moment, the most important thing is to be part of the development, to keep pushing the envelope and see what is achievable. And to work with the standards authorities. The CAA, FAA and EASA are all trying to grapple with this new technology. It is a good time to be involved but it could be a cash drain if you’re not careful.
IH: You mentioned international agencies. Have you been affected by Brexit?
AB: Working outside the UK is a challenge and our solution is to set up overseas offices in Europe and the US just to make sure we have a seat at the table. Paperwork and politics cause the most problems.
In fact, our US office only opened in February 2025. It is located in McLean, VA, where four of the top five defence contractors have operations, as well as being close to the Pentagon in Washington, DC.
IH: You are a member of the Farnborough Aerospace Consortium?
AB: I think member bodies are extremely important these days but they need to be about more than just collecting more members. Collaboration should be the driving force to make sure the industry stays strong and is well represented. Unfortunately, SMEs tend to be not very good at this, being very protective and not looking at the bigger picture to see where they could link with other like-minded organisations to get on different platforms and win better business.
Equally, the large OEMs have to work with SMEs and understand that they are part of the solution. They are not going to steal any business but they can provide a rapid response to a problem that the larger company will not be able to react to with the same speed, just because of the size and complexity of the organisation.
Trade organisations should be constantly pushing this message, that everyone should be working together. There is a need for each side to learn the other’s language because, when you get down to it, we’re talking about the same thing for the same reason.
IH: What other sectors is Barnbrook involved with?
AB: The UK’s rolling stock leasing companies and franchise operators form a significant part of the company’s business, where we supply reengineered brake controllers for trains. Our tracking and monitoring technology is also used in the transport industry, to help ensure on time performance. That covers maritime, buses and freight operations.
And we still have an interest in reverse-engineered ‘sunset and legacy’ products and systems for which operators can no longer find replacements or fix – such as engine controls and speed switches for older combat aircraft. That dates back to the time of my father and companies such as Plessey and TRW.
IH: How do you see the recovery from COVID?
AB: From a business point of view, there are fewer commercial aircraft flying, but they are newer models, so demand is lower for components for older aircraft. There are still staff shortages, so it is important to bring youngsters through, even if that can be a challenge at times – they tell me I’m too useful to retire!
We actually have a two tier training system. A two year traineeship programme with several local colleges includes two days a week at Barnbrook as their work placement., with the work carried out in line with the course requirements. The best candidates are then offered a full, four-year apprenticeship with the company. This again involves the colleges, for suitable additional courses.
By Ian Harbison
