Calender drive failure prompts upgrade at Colne Valley Rubber

Reddich, UK  – When a critical drive system failure brought production at Colne Valley Rubber to a standstill, the company required more than a temporary repair, according to a case study issued by Reddich-based industrial motor supplier WEG

Faced with obsolete equipment and increasing downtime, it said, the rubber processor needed a reliable upgrade that could restore operations quickly while improving the long-term performance of its forming line.

Working with drive systems specialist Westin Drives, WEG explained how it helped deliver a complete retrofit that replaced the failed drive arrangement with a modern, energy-efficient system.

The failure, it said, occurred when the main drive system on Colne Valley Rubber’s forming line experienced a "catastrophic breakdown" involving a Heenan Eddy current coupling drive system.

Despite attempts to source replacement components and repair the existing equipment at the Huddersfield, UK-based rubber company, the fault could not be resolved.

Having assessed the application, Westin developed an upgrade strategy, based on a “future-proof system that could integrate with the existing machine infrastructure while improving operational performance.”

As part of the retrofit, Westin installed a WEG 55 kW IE4 motor, selected for its high efficiency, reliability and suitability for demanding industrial applications, according to WEG’s case-study report.

To ensure compatibility with existing equipment, the team “precision-machined mounting plates to match the original motor centre height” and installed an SKF insulated bearing to further improve motor lifespan.

“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,” said Marek Lukaszczyk, WEG marketing manager of UK and Middle East.

“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 established system.

Mechanical modifications were carried out to complete the installation, including adapting the existing coupling to suit the new motor shaft and laser-aligning the motor with the existing gearbox.

The upgrade, stated WEG, restored full production with “minimal” downtime, eliminated dependence on obsolete components and provided Colne Valley Rubber with a more reliable and efficient drive system for the future.

“When our main calendar drive system failed, it brought production at Colne Valley Rubber to a standstill,” summarised Colne Valley Rubber MD John Ridsdale. “The retrofit modernised a critical machine, improved reliability and gave us much greater confidence moving forward.”