BEP Surface Technologies breathes new life into older equipment

BEP Surface Technologies, a leading electroplating and surface finishing specialist, has embarked on a £600,000 project to transform a 70-year-old Churchill TWR roll grinder into a state-of-the-art flagship of UK precision engineering.    

In partnership with Siemens and Made Smarter, the grinder is undergoing a complete mechanical and electrical overhaul to deliver tolerances as fine as 0.001mm.

The two-year refurbishment project, now 30% complete, is set to significantly expand BEP’s capacity and capability, enabling the company to produce ultra-precise finishes for high-growth sectors such as electric vehicle batteries and carbon fibre manufacturing, while reshoring critical capability to the UK.

Machine 22, as it is known at BEP, was built in the 1950s to meet the ultra-precise standards of today’s advanced manufacturers. The company acquired the machine a few years ago as part of its investment and growth strategy from a former supplier in the paper industry.

This machine is now being transformed into a high-spec digital flagship as part of BEP’s long-term investment strategy.

The upgrade equips Machine 22 with a Siemens SINUMERIK One CNC control and a SINAMICS S120 drive system, enabling BEP engineers to grind rollers to tolerances five times finer than before. This digital control integration will also allow BEP to document precision machining processes, ensuring traceability and quality assurance for customers.

The integration work is being carried out by Machine Code Engineering, which will source the Siemens system directly, install and program it into the machine, and complete all associated electrical work. Machine Code will also provide five days of operator training to ensure BEP’s team can fully utilise the upgraded system.

At BEP, the project is being led by Jamie Needham, BEP’s Project Manager, who began his career with the company as an apprentice at the age of 18. Now 25, Jamie has already overseen major investment programmes, including the pit refurbishment of BEP’s electroplating department.    

“Our existing grinders are capable of 0.005mm tolerances, but that’s not enough for many of the enquiries we receive,” Needham explained. “Machine 22 will allow us to say yes to work we’ve had to turn away in the past. The integration of Siemens SINAMICS S120 drive controls enables us to deliver precision of 0.001mm, placing us in a completely different league.

“For me, it’s a fantastic opportunity to take a generational machine and give it new life with modern technology, while keeping operator skill and judgement at the heart of the process. It’s an exciting blend of heritage and innovation.”

This project builds on BEP’s recent £650,000 refurbishment of its electroplating department, marking another significant reinvestment in the business. With labour, technology, and training included, the total value of the Machine 22 upgrade exceeds £600,000, reflecting BEP’s long-term commitment to ultra-precision engineering and advanced manufacturing capabilities.

Andrew McClusky, Managing Director of BEP Surface Technologies, said: “This project takes a second-hand machine with industrial heritage and transforms it into one that will serve the next generation of UK manufacturing.

“It is a flagship project that shows how we can use digital technology, in partnership with Siemens and Made Smarter, to push the boundaries of precision engineering. By achieving tighter tolerances and higher quality standards, we are enhancing our capabilities, securing new business, and ultimately helping our customers innovate and compete globally.”

Will Kinghorn, Technology Adoption Specialist at Made Smarter, said: “The project demonstrates how taking an older machine and refurbishing it with modern controls and adding sensors can not only give it a new lease of life but also increase its capability to a world-class level.

“BEP strives for tighter tolerances, higher quality, and improved customer service, which is achieved by investing in bold projects like this. Projects like BEP’s are precisely why the Made Smarter programme is supporting manufacturers to digitise, they lead to significant improvements in productivity, sustainability and staying competitive.

Mark Coombes, Head of Machine Tool Systems for Siemens in the UK & Ireland, said: “We’re proud to support BEP Surface Technologies in unlocking new levels of ultra-precision capability. By integrating our latest SINUMERIK controllers and SINAMICS drive systems, we are breathing new life into a legacy machine and helping to strengthen the UK manufacturing sector. It’s a great example of how digital technology can enable innovation, improve competitiveness, and bring critical capability back to British industry.

“Retrofitting a large machine tool is a strategic investment that not only leads to substantial energy cost savings but also significantly contributes to environmental protection by reducing resource consumption and waste, aligning with modern sustainability goals.”

With a swing diameter of 1,800mm and a between-centres capacity of 8,000mm, Machine 22 can carry over 20 tonnes, making it one of the UK’s most capable grinding platforms. These specifications allow BEP to tackle large roller projects, positioning the company as a preferred partner for manufacturers needing scale and precision.

The investment also addresses a market gap. Currently, UK companies in fast-growing sectors, such as EV batteries and composites, are sending rollers to Europe because they cannot achieve the required tolerances domestically.

By bringing this capability to Manchester, BEP will reduce costs, shorten lead times, cut carbon emissions, and strengthen UK supply chains. Customers already include industry leaders such as TetraPak and Syensqo, who rely on ultra-precise rollers for packaging and carbon fibre production. 

McClusky added, “Machine 22 is a flagship project that demonstrates BEP’s drive to lead in ultra-precision engineering. With Siemens’ technology and Made Smarter’s backing, we are taking a proven workhorse and transforming it into a system capable of world-class tolerances. This investment strengthens our position as a go-to partner for ultra-precision manufacturing and underlines our commitment to innovation, our workforce, and our customers.”