When a drive system failure brought production to a standstill at Colne Valley Rubber, the company required more than a temporary repair. Faced with obsolete equipment and increasing downtime, the company needed an upgrade that could restore operations quickly while enhancing the long-term performance of its forming line
Working with Westin Drives, drive system specialists, WEG delivered a complete retrofit, replacing the failed drive arrangement with a modern, energy-efficient system.
The failure occurred when the main drive system on Colne Valley Rubber’s forming line experienced a breakdown involving a Heenan Eddy current coupling drive system. The fault could not be resolved, despite attempts to source replacement components and repair the existing equipment, leaving the manufacturer facing production disruption.
After an electrical engineering partner referred them, Westin Drives assessed the application and developed a complete upgrade strategy. Instead of replacing obsolete components with another short-term solution, the team designed a future-proof system that could integrate with the existing machine infrastructure while improving operational performance.
As part of the retrofit, Westin Drives installed a WEG 55kW IE4 motor, selected for its high efficiency, reliability, and sustainability for demanding industrial applications. To ensure compatibility with the existing equipment, the team precision-machined mounting plates to match the original motor centre height and installed an SKF insulated bearing to enhance motor lifespan.
Marek Lukaszczyk, marketing manager for the UK and the Middle East, said, “When a critical machine stops, manufacturers need a solution that goes beyond restoring operation; they need confidence that the equipment will continue performing reliably in the future. By combining WEG’s high-efficiency motor technology with Westin Drives’ retrofit expertise, this project demonstrates how modern drive solutions can extend the life of existing machinery while improving energy performance and reliability.”
The new motor was integrated into the existing control system, which was mounted alongside the existing control panel and configured to work with the customer’s system. A new operator control station was also designed and built to maintain familiarity for machine operators while introducing updated technology.
Mechanical modifications were conducted to complete the installation, including adapting the existing coupling to suit the new motor shaft and laser-aligning the motor with the existing gearbox. This multidisciplinary approach, combining mechanical engineering, electrical integration, and software expertise, helps minimise disruption and ensures a seamless transition to the new system.
John Ridsdale, managing director at Colne Valley Rubber, said, “When our main calendar drive system failed, it brought production at Colne Valley Rubber to a standstill. Westin Drives responded quickly, understood the urgency and delivered a long-term solution rather than a temporary repair. The retrofit modernised a critical machine, improved reliability and gave us much greater confidence moving forward.”
The upgrade restored full production with minimal downtime, eliminated dependence on obsolete components, and provided Colne Valley Rubber with a more reliable and efficient drive system.
Fraser Lynch, operations director at Westin Drives, said, “This project demonstrates the importance of combining rapid response with practical engineering and long-term reliability. Instead of repairing obsolete equipment, we delivered a modern solution that integrated with the customer’s existing setup and improved the performance of a critical production asset.”
Combining energy-efficient motor technology with specialist retrofit engineering enables WEG and Westin Drives to help manufacturers improve equipment reliability and extend the operational life of industrial assets.
