Custom Production Machine
Custom Production Machine for 50,000 Unit Export Order
A long-standing manufacturing customer secured a major export order for 50,000 drainage bungs destined for Saudi Arabia. Each bung required a butterfly nut to be fitted manually, making production far too slow to meet the customer’s deadline.
Rather than purchasing expensive automation equipment with long lead times, they asked IGS Electrical to design a practical, cost-effective solution that could be built quickly.
We designed and manufactured a bespoke production machine around the customer’s existing process. A geared electric motor was fitted with a custom-machined acrylic drive wheel, precision milled to locate the threaded drainage bung while gripping and rotating the butterfly nut into position.
The drive wheel was carefully profiled so that once the nut reached the correct tightness it naturally released from the wheel, allowing the operator to remove the completed component and load the next one without stopping production.
The machine was operated using a foot switch, leaving both hands free for loading and unloading parts and dramatically increasing production speed. Electrical controls, emergency stop facilities and mechanical assembly were all completed in-house to provide a safe and reliable production aid.
By designing a bespoke solution instead of purchasing specialist equipment, the customer kept costs to a minimum while successfully completing the entire 50,000 unit export order on schedule.
This project demonstrates IGS Electrical’s ability to combine electrical engineering, practical manufacturing knowledge and problem solving to deliver bespoke industrial machinery tailored to individual production requirements.
