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Holistic Approach to Production Line Improvement

Project Brief

In late 2018, Motion Drives & Controls was approached by a customer seeking to improve the braking system on one of their production lines. The customer, a specialist in tubing production, was dealing with a significant issue of expensive scrap produced during setup. The tubing produced had a non-permeable membrane added partway through the extrusion process, enabling its use in brown field sites. The project was delayed due to Covid-19 restrictions but was completed in 2021.

Old System

The old system was primarily focused on the production of specialist tubing. However, it had a significant issue with the braking system, which was not efficient enough for the production line. The start-up process, particularly when changing from one size pipe to another, was extremely slow and frustrating for the operators. This inefficiency led to a high production of scrap during setup, which was costly for the company.


  • Inefficient braking system leading to production delays
  • Slow and frustrating start-up process when changing pipe sizes
  • High production of expensive scrap during setup

New System

Rather than just adding a new braking system, Motion Drives & Controls proposed a holistic approach to the customer. A new unwind assembly was built, incorporating improved control along with quick setup features to enhance changeover. This new system was integrated into the production line in 2021. The new system immediately showed benefits, with start-up times dropping by 85% and scrap dropping to less than 10% of their previous levels.

Motion Drives & Controls' philosophy is to always try to exceed the customers’ expectations. This project is a testament to that commitment, with the holistic approach bringing massive savings in both money and landfill scrap, thereby reducing costs significantly.


  • Improved braking system leading to faster production times
  • Quick setup features enhancing changeover and reducing operator frustration
  • Significant reduction in scrap production, leading to cost savings
  • Rapid return on investment, with the equipment paying for itself in less than 6 months of running
  • Additional benefits of reduced landfill costs, both financial and environmental