Rapid Response Control System for Bakery Production Line

The Problem 

Moorland Engineering was contacted by a local bakery facing a critical machinery breakdown. The machine, which applies fondant images onto biscuits, relies on a pair of upper and lower rollers to compress and fold fondant to the required thickness before application. A gearbox within this system had failed, and the lead time for a replacement part was an unworkable 20 weeks. Immediate action was required to avoid prolonged downtime and potential disruption to the bakery's operations. 

The Solution 

To eliminate the need for a replacement gearbox, Moorland Engineering approached T-T Controls & Automation® with a request for a bespoke control system. The solution involved: 

Products & Services Delivered 

The Results 

Thanks to the rapid turnaround and innovative solution, the bakery was able to resume operations immediately, completely avoiding the anticipated 20-week delay caused by the failed gearbox. The machine's functionality was not only restored but also enhanced through the use of Variable Speed Drives, providing greater control and flexibility. Additionally, the new control system contributed to improved energy efficiency and a modernised operational setup, offering long-term benefits beyond the immediate repair. 

Customer Feedback 

“We can always rely on T-T to meet the demands of our business and tight deadlines as we often work on a highly reactive basis dealing with breakdowns. In addition to this, we have used T-T for planned upgrade works — including volume control panels for clients transitioning from Direct-on-Line to Variable Speed Drives — offering them substantial savings on energy consumption and electrical expenditure.” 
— Moorland Engineering