Custom Pneumatic Cylinder Prevents £4.3 Million Downtime at Pharmaceutical Manufacturer
When a critical loader failed overnight at a UK pharmaceutical manufacturing facility, production of vital medication came to an immediate halt.
The cause was traced to a failed pneumatic cylinder, leaving an essential machine completely out of service.
Case Study Overview
Sector: pharmaceutical manufacturing
Challenge: a failed critical loader required a bespoke replacement cylinder, with the original supplier quoting an 18 day OEM lead time.
Solution: same day UK manufacture and dispatch of a custom pneumatic cylinder in partnership with HAYLEY DEXIS.
Products / technology used: custom pneumatic cylinder, UK based express cylinder service and Camozzi assembly capability.
Result: critical production restored within 24 hours, helping prevent approximately £4.3 million in downtime related losses.
Situation: Critical Production Halt at a UK Pharmaceutical Facility
When a critical loader failed overnight at a UK pharmaceutical manufacturing facility, production of vital medication came to an immediate halt. The cause was traced to a failed pneumatic cylinder, leaving an essential machine completely out of service.
With no spare cylinder available on site and the original machine manufacturer unable to provide emergency support, the maintenance team carried out a temporary repair simply to minimise disruption while a permanent solution could be found.
The pharmaceutical manufacturer contacted its local HAYLEY DEXIS branch, whose emergency response team quickly assessed the situation and began working with Camozzi Automation UK to identify a long term replacement solution.
Challenge: Replacing an 18-Day OEM Lead Time
Following receipt of a drawing of the failed cylinder from HAYLEY DEXIS, Camozzi's technical team assessed the application swiftly.
Although the original component had been manufactured as a bespoke pneumatic cylinder, and the customer was facing an estimated 18-day OEM lead time for a replacement.
For a critical pharmaceutical production line, waiting several weeks for the original supplier was not a practical option. The customer needed a fast, reliable and application specific pneumatic solution that could restore production as quickly as possible.
Solution: Same Day Custom Pneumatic Cylinder Manufacture
Camozzi’s technical team determined that a replacement could be produced by making only minor modifications to the original pneumatic cylinder design.
Using Camozzi’s UK based express cylinder service and in-house assembly capability, the team manufactured and dispatched the replacement custom pneumatic cylinder the very same day. This allowed the customer to restore production without waiting weeks for the original supplier.
The close collaboration between HAYLEY DEXIS and Camozzi Automation UK ensured the customer received both rapid technical support and a practical engineering solution when time was critical.
Result: Production Restored Within 24 Hours
The replacement cylinder arrived on site and was installed by 7:00pm, with the loader fully operational again by 9:00pm on the same day the issue was reported.
By replacing an 18 day lead time with a same day engineered solution, Camozzi Automation UK and HAYLEY DEXIS helped the customer:
• Prevent downtime related losses: helped prevent approximately £4.3 million in potential downtime costs.
• Restore critical production: brought the loader back online within 24 hours of the initial failure.
• Support healthcare supply: helped maintain the manufacture of vital medication for the UK healthcare sector.
• Reduce operational risk: provided rapid engineering support and local technical expertise when the original replacement route was not fast enough.
Why Camozzi Automation UK?
When production stops unexpectedly, waiting weeks for replacement components isn’t an option.
Camozzi Automation UK combines engineering expertise with UK manufacturing and assembly capabilities to provide fast, application specific pneumatic solutions for critical industrial environments.
Whether replacing obsolete components, modifying existing designs or supplying custom pneumatic cylinders, our team work closely with trusted distribution partners such as HAYLEY DEXIS to minimise downtime and keep production moving.
Key Benefits Delivered for the Customer
- Rapid replacement cylinder support: Camozzi manufactured and dispatched a custom pneumatic cylinder when the original supplier could not provide emergency support.
- 18 day OEM lead time avoided: a bespoke engineering solution helped the customer avoid waiting weeks for a replacement component.
- Strong distributor collaboration: Camozzi Automation UK and HAYLEY DEXIS worked together quickly to assess the issue and support the customer.
- Major downtime risk reduced: the response helped prevent approximately £4.3 million in potential downtime related losses.
- Critical production restored: the loader was operational again within hours, helping maintain pharmaceutical production.
Need a Custom Pneumatic Cylinder or Urgent Replacement?
Speak to Camozzi Automation UK about custom pneumatic cylinders, replacement pneumatic components and rapid application support for critical industrial equipment.
If your site is dealing with a failed cylinder, obsolete part, long OEM lead time or urgent production issue, our technical team can help review the application and discuss a suitable replacement route.