UK Rubber Factory Upgrades Drive System with WEG 55kW Motor

en.Wedoany.com Reported - WEG, in partnership with drive system specialist Westin Drives, has completed a comprehensive upgrade of the forming line drive system for rubber processor Colne Valley Rubber. The project replaced a failed drive unit with a modern, energy-efficient system, restoring production with minimal downtime while improving long-term operational reliability and energy efficiency.

The failure was caused by a catastrophic breakdown of a Heenan eddy current coupling drive unit in the main drive system of Colne Valley Rubber's forming line. The plant attempted to source replacement parts and repair the original equipment, but the issue could not be resolved, leaving production facing severe disruption. Following a recommendation from an electrical engineering partner, Westin Drives conducted an on-site assessment and developed a complete upgrade strategy. Rather than applying short-term alternatives to obsolete components, the team designed a future-proof system that could integrate with the existing machine infrastructure while enhancing operational performance.

Westin Drives installed a WEG 55 kW IE4 motor for the upgrade, selected for its high efficiency and reliability in demanding industrial applications. To ensure compatibility with existing equipment, the team precision-machined the mounting baseplate to match the original motor's center height, and fitted SKF insulated bearings to extend motor life. Marek Lukaszczyk, WEG UK and Middle East Market Manager, said: "When a critical machine stops, manufacturers need more than just a return to operation—they need confidence that the equipment will continue to run 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 service life of existing equipment while improving energy performance and reliability."

The new motor was integrated into the existing control system, with the control cabinet positioned alongside the original control panel and configured to operate in coordination with the customer's existing system setup. The team also designed and built a new operator control station, introducing updated technology while maintaining familiarity for machine operators. Mechanical modifications carried out during the installation phase included adjusting the existing coupling to suit the new motor shaft and using laser alignment to precisely align the motor with the existing gearbox. The entire project combined mechanical engineering, electrical integration, and software expertise to minimize production disruption and ensure a smooth transition to the upgraded system.

John Ridsdale, Managing Director of Colne Valley Rubber, said that production came to a standstill when the main calender drive system failed. Westin Drives responded quickly, understood the urgency of the issue, and delivered a long-term solution rather than a temporary repair. The upgrade has modernized critical equipment, improved reliability, and given the company greater confidence for the future.

Following the upgrade, the plant returned to full production with minimal downtime, no longer reliant on obsolete components, and now benefits from a future-proof drive system that is more reliable and efficient. Fraser Lynch, Operations Director at Westin Drives, said the project demonstrates the importance of combining rapid response, practical engineering, and long-term reliability; rather than simply repairing outdated equipment, the approach delivered a modern solution that integrates with the customer's existing facilities and improves the performance of critical production assets.

Through the combination of high-efficiency motor technology and specialist retrofit engineering, WEG and Westin Drives continue to support manufacturers in improving equipment reliability and extending the service life of industrial assets.