At Mount Filling Systems, we believe that servicing a machine should never be about simply fixing today’s problems, it should be an opportunity to improve tomorrow’s performance.
That type of philosophy was recently demonstrated during a major refurbishment project for ROCOL.
They are one of the UK’s leading manufacturers of specialist industrial lubricants and maintenance products, with a heritage spanning more than 145 years. Based in Leeds and now part of Illinois Tool Works (ITW), ROCOL develops and manufactures premium lubrication solutions for some of the world’s most demanding industrial sectors, including aerospace, defence, food manufacturing, power generation and heavy engineering.
Their reputation for technical excellence, product quality and continuous innovation makes them one of Mount Filling Systems’ key strategic customers, and we are proud to support their ongoing investment in advanced manufacturing and filling technology.
The project centred around a portable liquid filling machine that had been a small but important part of ROCOL’s production operation for well over a decade. Despite its age, the machine had remained reliable and productive throughout its working life. However, years of continuous use and increasing production demands meant that it was beginning to show the inevitable signs of wear.
Looking Beyond Routine Maintenance
As the custodians of the Mount Packaging Systems legacy, we are committed to maintaining the highest standards across every machine we support.
Rather than carrying out a standard service and replacing a handful of worn components, we proposed a far more comprehensive solution but a complete machine overhaul designed to restore long-term performance, improve reliability and reduce future maintenance requirements.
The machine was completely stripped down to its individual components.
The frame was dismantled, inspected and repaired where necessary. Components were sandblasted to remove years of wear and contamination. Structural elements were re-welded, damaged sections were remanufactured, and the entire machine was professionally powder-coated in our signature Mount Blue finish.
The objective was simple: rebuild the machine not just for today, but for the next decade of operation.
Re-Engineering the Critical Components
The most significant improvements were focused on the heart of the filling system.
Critical wear components, including the pump barrel and the valves responsible for drawing liquid into the measuring chamber before each fill cycle, were carefully evaluated and replaced.
Rather than simply installing like-for-like components, we undertook a redesign of the control system using advanced pneumatic technologies specifically suited to handling industrial oils and lubricants.
This required extensive engineering work and careful component selection. Working with world-leading pneumatic control suppliers, we sourced specialist technologies manufactured in Japan that were specifically designed for demanding oil-handling applications.
The goal was not merely to maintain the machine’s original performance but to improve it. Every design decision was focused on delivering greater reliability, longer service intervals and improved operational consistency.
Creating a Better Experience for Operators
While many engineering projects focus solely on technical specifications, we believe the operator experience is equally important. In our experience, what engineers want from a machine and what operators need from a machine are often two different things.
Engineers may focus on technical capability, while operators simply need equipment that works consistently, safely and without complication.
Throughout this project, we invested significant time in considering how the machine would be used on a daily basis. The result is a filling machine that is simpler to maintain, requires less operator intervention and delivers more consistent filling performance.
Reduced maintenance requirements mean less downtime, simplified operation reduces training requirements and operator workload, improved reliability creates a more predictable production environment.
Most importantly, it allows operators to focus on productive work rather than dealing with machine-related issues.
Our goal is simple: we want operators to have a boring day.
A boring day in manufacturing is often a sign that everything is working exactly as it should.
No breakdowns. No unnecessary adjustments. No unexpected interruptions. Just smooth, reliable production.
Delivering Long-Term Return on Investment
By choosing a comprehensive filling machine refurbishment rather than a basic service, ROCOL has gained significantly more value from its investment.
The machine now benefits from:
Fully refurbished mechanical systems
New critical wear components
Redesigned pneumatic controls
Improved reliability and consistency
Reduced maintenance requirements
Enhanced operator usability
Extended machine lifespan
Lower long-term operating costs
Most importantly, the machine has been restored to a standard that allows it to continue delivering performance levels comparable to its original factory-built specification for many years to come.
Engineering for the Future
At Mount Filling Systems, we believe that great engineering goes the parts are connected together. It involves understanding how equipment is used, how operators interact with it and how manufacturers can achieve the greatest return from their assets.
This project with ROCOL demonstrates our commitment to helping manufacturers maximise the value of their filling machinery through intelligent refurbishment, thoughtful redesign and engineering excellence.
Whether we are servicing a machine, upgrading a filling system or designing bespoke liquid packaging equipment from scratch, our objective remains the same that is to create reliable, user-focused machinery that helps manufacturers operate more efficiently, easily, more productively and enjoy their days work
So, in our humble opinion, building great machines is about great parts and a lot of heart !