Case Study: Rapid Gearbox Replacement Keeps a Berkshire Flour Mill Running

When a local flour mill in Berkshire suffered an unexpected breakdown, a critical gearbox failure put production at immediate risk. Branch Manager Ian Nesbit knew the priority was clear: identify the unit quickly, find a workable replacement, and get the site back up and running with minimal disruption.

The mill sent across photos of the gearbox and ID plate to speed up identification. However, it quickly became apparent that the original manufacturer was no longer trading, which removed the straightforward route of sourcing an exact OEM replacement and increased the risk of extended downtime.

To remove guesswork and accelerate the process, Ian arranged for the gearbox to be collected the same day by the Berkshire delivery van. With the unit in hand, he took precise measurements, created an accurate drawing, and used this to specify an equivalent replacement gearbox. The new unit was a close match for the application but required a new bush due to a difference from the original configuration.

Working with one for our product partners, Ian confirmed the specification and placed the order that day. The replacement gearbox was delivered back to the mill the next day, allowing the team to restore operation quickly and with confidence in the fit and function of the unit.

Given the gearbox’s critical role in the process, Ian also discussed whether repairing the original unit could be worthwhile, so the mill would have a back-up ready if it happened again. After assessing the options, it was clear the repair route would cost over £1,000 more than the replacement gearbox that was already installed and running. To reduce future risk and support maintenance planning, the customer chose to order a spare gearbox as a standby item.

The result was a fast, practical solution that protected uptime, avoided the delays associated with obsolete parts, and left the site in a stronger position for the next unplanned failure, saving time, reducing maintenance pressure, and helping prevent repeat downtime.

 

This is just one of the ways our local branch teams help customers get back up and running fast, with practical support you can rely on. It saves time, reduces downtime, and keeps maintenance plans on track. Find your local branch here.