BEP Surface Technologies, a specialist electroplating and surface finishing, is undertaking a £600,000 project to modernise a 70-year-old Churchill TWR roll grinder into a high-tech high precision machine tool.
In collaboration with Siemens and Made Smarter, the comprehensive mechanical and electrical refurbishment of ‘Machine 22’ will enable the machine to achieve tolerances as fine as 0.001mm, significantly enhancing BEP’s capabilities for high-growth sectors such as electric vehicle batteries and carbon fibre manufacturing.
The upgrade is a strategic investment to expand BEP’s capacity and support reshoring of critical manufacturing capabilities to the UK. Originally built in the 1950s the grinder is now being equipped with advanced digital controls. The integration of Siemens SINUMERIK One CNC, servo motors, and SINAMICS S120 drive system will allow BEP engineers to deliver precision five times greater than before, with full traceability and quality assurance for customers.
Machine Code Engineering is responsible for sourcing, installing, and programming the Siemens system, as well as providing operator training to ensure BEP’s team can fully utilise the upgraded technology. Project Manager Jamie Needham, who began his career at BEP as an apprentice, leads the initiative. Needham notes that while existing grinders achieve 0.005mm tolerances, the upgraded Machine 22 will enable BEP to accept work previously out of reach, positioning the company at the forefront of ultra-precision engineering.
This project follows BEP’s recent £650,000 refurbishment of its electroplating department, further demonstrating the company’s commitment to reinvestment and innovation. The total value of the Machine 22 upgrade, including labour, technology, and training, exceeds £600,000.
Andrew McClusky, Managing Director of BEP, emphasises the significance of the project: “Transforming a second-hand machine with industrial heritage into a state-of-the-art system will serve the next generation of UK manufacturing. By leveraging digital technology in partnership with Siemens and Made Smarter, we are pushing the boundaries of precision engineering, enhancing our capabilities, and supporting our customers’ global competitiveness.”
Will Kinghorn, Technology Adoption Specialist at Made Smarter, highlights the impact of refurbishing legacy equipment with modern controls and sensors: “Projects like BEP’s demonstrate how digitisation can dramatically improve productivity, sustainability, and competitiveness.”
Mark Coombes, Head of Machine Tool Systems for Siemens UK & Ireland, adds: “Integrating SINUMERIK controllers and SINAMICS drive systems breathes new life into legacy machines, strengthening UK manufacturing and supporting sustainability goals through energy savings and reduced resource consumption.”
With a swing diameter of 1,800mm, a between-centres capacity of 8,000mm, and the ability to carry over 20 tonnes, Machine 22 is now one of the UK’s most capable grinding platforms. This investment addresses a market gap, enabling BEP to deliver ultra-precise rollers domestically for sectors such as EV batteries and composites, reducing costs, lead times, and carbon emissions while strengthening UK supply chains.
Photo: Mark Coombes, Head of Machine Tool Systems for Siemens in the UK & Ireland, Andrew McClusky, Managing Director, BEP Surface Technologies and Will Kinghorn, Technology Adoption Specialist at Made Smarter