Market Sector:
PHARMACEUTICAL
CUSTOMISED MANUFACTURING
CSI CASE STUDY
The value of having a local manufacturing partner for your machine improvement journey
Coating Systems International (CSI), based on the Woolpit Business Park near Bury St Edmunds, specialises in developing precision tablet coating machines and spray nozzles for the global pharmaceuticals sector and related industries. It uses the latest technology and finest materials to create products that meet clients’ specific requirements and the highest quality standards.
The company started designing and manufacturing its TechniCota range of machines in 1996. Over the next 20 years it became so successful that it had to outsource some of that production to keep up with demand. “At one stage we started using an American engineering firm after one of our distributors in the USA recommended them,” explains CSI’s Managing Director Sean Stuteley.
“However, because they were 3,500 miles away, we were not 100% in control of the process. That caused issues when we wanted to make incremental improvements to reflect changing customer and regulatory demands. In short the American firm wasn’t able to do the work and we needed to bring manufacturing back to the UK to manage quality and costs.”
Our tablet coating machines are workhorses, they are not glamorous but they are built to last, which is what our customers want. As such, they look like fairly easy machines to manufacture but in fact they are incredibly complex to make, which is a challenge for your standard machine shop.
Sean Stuteley, CSI’s Director
Our tablet coating machines are workhorses, they are not glamorous but they are built to last, which is what our customers want. As such, they look like fairly easy machines to manufacture but in fact they are incredibly complex to make, which is a challenge for your standard machine shop.
Sean Stuteley, CSI’s Director
WE WANTED MORE THAN A SUB-CONTRACTOR
That’s when Sean started looking for a machine engineering specialist nearer to home. “We wanted more than a sub-contractor, we wanted them to be our manufacturing partner. Unfortunately, the first company we used failed to come up to spec and we had to scrap their machine.
“Our tablet coating machines are workhorses,” he explains, “they are not glamorous but they are built to last, which is what our customers want. As such, they look like fairly easy machines to manufacture but in fact they are incredibly complex to make, which is a challenge for your standard machine shop.
“They are also specialist machines (with probably fewer than 1000 machines like them in the UK), which means we expect to build only around four a year.”
One of Sean’s colleagues suggested that he contact Will Bridgman at Warren. “I’d heard of them and talked to them about making some small parts in 2016 – but this time, in December 2018, we asked them to look at the whole machine. We explained the challenges we faced and the improvements we wanted to make, and Will said his team could do the work.
A RELATIONSHIP BUILT ON RESPECT
“It was then that we really got to know Warren and I have to say I was surprised by the level of resources and skills they have. I was also impressed with their facilities and their commitment to excellence – plus being less than 20 miles from us was a massive tick in their favour.” That proximity made it easy for Warren’s designers and workshop team to visit CSI to go over the machine in detail.
Having gained a complete understanding of CSI’s needs, including all the incremental improvements they wanted, the Warren team started work building the new TechniCota 400.
This was the start of a year-long project and in some ways, it was a leap of faith for both companies. Not least because CSI had to invest in making their design drawings compatible with Warren’s software design system.
“Warren made us a good offer to help us take that leap – and reassured us that the designs would remain ours, which was vital because it meant they were not trying to lock us into the relationship.” At the same time, Warren had to invest in a new stainless-steel-only fabrication room to ensure there was no cross-contamination with other metals. “They were prepared to invest their time and expertise in the learning process and in adapting their manufacturing processes to meet our needs.”
COLLABORATING ON DESIGN AND MANUFACTURING
We tested it in our workshops before shipping it out,” explains Sean, “so we knew it was a fantastic machine.
Sean Stuteley, CSI’s Director
We tested it in our workshops before shipping it out,” explains Sean, “so we knew it was a fantastic machine.
Sean Stuteley, CSI’s Director
The two teams met regularly to discuss progress and iron out any issues. “Warren’s proximity meant our engineers could visit weekly and collaborate closely with their design and manufacturing teams. Warren put in the resources and, as a result, we were able to implement all the modifications we had wanted to do over the last 20 years to create a new version of the machine.
“Although the basics are currently the same, Warren has upgraded the machine to make it more hygienic and Good Manufacturing Process compliant.
“It is now a much better product all round and that will help us remain competitive in the market. Despite technical challenges, Warren completed the project on time and we shipped the new machine to our customer in Bulgaria in January 2020.”
That shipping was just before the first pandemic lockdown and CSI haven’t seen the machine since. However, they have heard from their customer that the machine is running well. “We tested it in our workshops before shipping it out,” explains Sean, “so we knew it was a fantastic machine.”
DESIGN-TO-MANUFACTURE
It helps to have a good relationship and one that’s built on shared business ethics, authentic values and a clear vision of the future. You can see that in the way Warren invests in its capabilities and people. As a result, we’ve pulled together and got what we wanted.
Sean Stuteley, CSI’s Director
It helps to have a good relationship and one that’s built on shared business ethics, authentic values and a clear vision of the future. You can see that in the way Warren invests in its capabilities and people. As a result, we’ve pulled together and got what we wanted.
Sean Stuteley, CSI’s Director
Warren has now started work on a second machine and this time they are making some more fundamental changes. “We always saw this as a long-term journey of improvement,” says Sean, “so after giving the first machine a facelift, Warren’s design-to-manufacture experts are now advising us on enhancements that will make it easier to build. That’s the real benefit of having a reliable, willing and local manufacturing partner, rather than just using ad-hoc contractors.
“It helps to have a good relationship and one that’s built on shared business ethics, authentic values and a clear vision of the future. You can see that in the way Warren invests in its capabilities and people. As a result,” concludes Sean, “we’ve pulled together and got what we wanted.”
Report by Huw Sayer at Business Writers Ltd for Warren.
