Contact Liverpool 24/7 T: 0151 207 2074
Contact Wallasey 24/7 T: 0151 652 1315
Contact Manchester 24/7 T: 0161 702 8737

£70,000 per annum cost reduction for food processer

RJW Intelligent Engineering Solutions > £70,000 per annum cost reduction for food processer

Project background

Our customer was incurring very high costs and extended lead-times refurbishing food processing rollers. The assemblies had to be fully stripped and sent abroad to be reground. Removing the end bearings rendered them unserviceable, so each repair cycle required the purchase and installation of new bearings. Multiple third parties were involved in the repair process. Concerns over the impact of Brexit also figured highly in our customer’s considerations.

11

Challenge

Our brief was to significantly reduce the turnaround time and costs associated with the refurbishment of these process critical assets. Our customer was keen to see ownership of the task invested in one UK supplier. The potential for multiple bottlenecks needed to be reduced, in addition to the very high cost (£20,000) of replacing serviceable bearing assemblies to facilitate the machining of the roller face.

Solution

RJW’s Mechanical Services Manager proposed an innovative solution that involved the removal and machining of the rollers without removing the bearings and housings. Not only did this eradicate the labour cost of stripping down and reassembly, it also removed the need to purchase new bearings on each repair cycle. Given the proximity of RJW’s workshop, savings were also realised in transport costs, and the lead time was significantly reduced from 3 weeks to 5 days.

Project Stats
£0
Saving per roller
0week
Lead time reduced from 3 weeks

Success Stories

11

Generating success for renewable energy pioneers

To develop the means of capturing and converting the ebb and flow of underwater tidal currents into electricity, RJW was tasked with creating a pioneering new turbine generator.
11

Reduction in energy bill for premium plastics processor

A premium plastics processor approached RJW Electronics Service Department to provide a solution that significantly reduced extruder running costs, improved process control and reduced maintenance costs.