IE4 motor technology helps rubber manufacturer modernise critical production equipment

(See WEG at MachineBuilding.Live, 14 October 2026, on stand 56)

When a critical drive system failure brought production at Colne Valley Rubber to a standstill, the company required more than a temporary repair. Faced with obsolete equipment and increasing downtime, the rubber processing specialist 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 helped deliver a complete retrofit that replaced the failed drive arrangement with a modern, energy-efficient system.

The failure 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, the fault could not be resolved, leaving the manufacturer facing significant production disruption.

After being referred by an electrical engineering partner, Westin Drives assessed the application and developed a complete upgrade strategy. Rather than replacing obsolete components with another short-term solution, the team designed a future-proof system that could integrate with the existing machine infrastructure while improving operational performance.

As part of the retrofit, Westin Drives installed a WEG 55 kW IE4 motor, selected for its high efficiency, reliability and suitability for demanding industrial applications. To ensure compatibility with the 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, 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. A new operator control station was also designed and built, maintaining familiarity for machine operators while introducing updated technology.

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. This multidisciplinary approach combined mechanical engineering, electrical integration and software expertise to minimise disruption and ensure a smooth transition to the upgraded system.

"When our main calendar drive system failed, it brought production at Colne Valley Rubber to a standstill. Westin Drives responded quickly, understood the urgency and delivered a long-term solution rather than a temporary repair," added John Ridsdale, Managing Director at Colne Valley Rubber. "The retrofit modernised a critical machine, improved reliability and gave us much greater confidence moving forward."

The successful upgrade 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.

"This project demonstrates the importance of combining rapid response with practical engineering and long-term reliability. Instead of repairing obsolete equipment, we delivered a modern solution that integrated with the customer's existing setup and improved the performance of a critical production asset," commented Fraser Lynch, operations director at Westin Drives.

By combining energy-efficient motor technology with specialist retrofit engineering, WEG and Westin Drives continue to support manufacturers in improving equipment reliability and extending the operational life of industrial assets.