Emergency drive system upgrade for rubber processing company

The Challenge: A rubber processing company experienced a critical breakdown on their rubber forming line when the main drive system failed. The issue was traced to a catastrophic failure of a Heenan Eddy current coupling drive system, bringing the entire factory production to an immediate halt.

Despite ordering critical spare parts, the fault could not be rectified. With production downtime escalating, the client required not only an urgent repair but a reliable long-term solution.

Another company had been unable to deliver a timely or cost-effective response, prompting referral to Westin Drives by an electrical engineering partner.

The objective was clear:

✅ Restore production quickly

✅ Remove obsolete equipment

✅ Deliver a future-proof, efficient solution

The Solution: A complete drive system upgrade was designed and implemented, combining fitting, machining, electrical, and software engineering expertise.

Key Components of the Upgrade

Motor Upgrade

• Installed a WEG 55kW IE4 motor for super premium efficiency

• Precision-machined mounting plates to match original centre height

• Fitted a SKF insulated bearing to increase motor lifespan

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Variable Speed Drive

• Specified and installed a Lenze i550 Protec IP55 Variable Speed Drive

• Mounted to the side of the existing control panel

• Fully integrated into the existing control system

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Operator Controls

• Designed and built a new operator control station

• Maintained familiarity with the original control method

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Mechanical Adaptation

• Existing coupling bored and slotted to suit the new motor shaft

• New motor was laser aligned with existing Radicon gearbox

The Result

✅ Full restoration of production with minimal downtime and ahead of schedule

✅ Drastically improved system efficiency

✅ Elimination of obsolete non-standard components

✅ Increased reliability and reduced risk of future breakdowns

✅ Seamless integration with existing infrastructure

Client Feedback: John Ridsdale, Managing Director

“When our main calendar drive system failed, it brought production at Colne Valley Rubber to a standstill. For a small manufacturing business, that kind of breakdown is extremely serious, and every day lost has a real impact on customers, cashflow, and confidence. From the moment Westin Drives became involved, their response was outstanding. They attended site quickly, understood the urgency immediately, and rather than offering a short-term repair to an obsolete system, they engineered a proper long-term solution. The retrofit was handled professionally from start to finish, covering the mechanical, electrical, installation, and commissioning work needed to get us running again. The new drive system has modernised a critical machine, improved reliability, and given us far more confidence moving forward. What impressed me most was not only the technical ability, but the attitude of the team. They were calm, practical, responsive, and genuinely understood how important this machine is to our business. Westin Drives completed the project ahead of schedule and helped us turn a very difficult situation into a major improvement for the future. I would have no hesitation in recommending them to any manufacturer needing expert drive system support, especially where downtime and reliability really matter.”

Westin Drives Perspective: Fraser Lynch, Operations Director – Westin Drives

“This project is a great example of how we approach critical breakdowns with fast response, practical engineering and long-term reliability at the core. Instead of patching obsolete equipment, we delivered a modern, energy-efficient solution fully integrated with the customer’s existing setup. Completing the work ahead of schedule while coordinating multiple engineering disciplines demonstrates the strength of our team and our commitment to keeping our customers running.”