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.
The Challenge
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 to identify a long-term replacement solution.
The Camozzi Solution
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 cylinder with an estimated OEM lead time of 18 days, Camozzi's technical team determined that a replacement could be produced by making only minor modifications to the original design.
Using our UK based express cylinder service and assembly capability, Camozzi manufactured and dispatched the replacement pneumatic cylinder the very same day, allowing the customer to restore production without waiting weeks for the original supplier.
The close collaboration between HAYLEY DEXIS and Camozzi ensured the customer received both rapid technical support and a practical engineering solution when time was critical.
The Results
The replacement cylinder arrived on site and was installed by 7:00 pm, with the loader fully operational again by 9:00 pm on the same day the issue was reported.
By replacing an 18-day lead time with a same-day engineered solution, Camozzi and HAYLEY DEXIS helped the customer:
• Prevent approximately £4.3 million in downtime-related losses
• Restore critical production within 24 hours
• Maintain the uninterrupted manufacture of vital medication for the UK healthcare sector
• Reduce operational risk through rapid engineering support and local technical expertise
Why Camozzi?
When production stops unexpectedly, waiting weeks for replacement components isn’t an option.
Camozzi 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 bespoke pneumatic cylinders, our team work closely with trusted distribution partners such as HAYLEY DEXIS to minimise downtime and keep production moving.
Key Benefits
• Same-day manufacture and dispatch of a custom pneumatic cylinder
• Bespoke engineering solution replacing an 18-day OEM lead time
• Rapid technical collaboration between Camozzi and HAYLEY DEXIS
• £4.3 million in potential downtime costs prevented
• Critical pharmaceutical production restored within hours