From Downtime to Flow: Restoring a Failing Conveyor Line

A regional packaging facility was experiencing severe productivity loss due to an ageing conveyor line: misaligned rollers, fluctuating sensor behaviour, and periodic electronic failures.
S&G Engineering performed a full diagnostic sweep using thermal scanning, vibration analysis, and load-tracking data.

Within 48 hours, our engineers identified the root causes: intermittent motor drive faults, failing optical sensors, and a structural misalignment creating unnecessary drag.
We rebuilt the drive assembly, replaced the sensors, recalibrated the entire line, and installed predictive maintenance monitoring to prevent future failures.

The result? A 62% reduction in unplanned stoppages, smoother product flow, and a fully stabilised system that now runs at peak reliability.