How Brown GearTech delivered a rapid, more durable gearbox solution in under 48 hours
Fortis IBA, runs high-capacity recycling and processing operations across the UK. In 2023, the group expanded into Sittingbourne, Kent, opening a new state of the art production facility to process commercial and municipal waste at scale.
Operating in abrasive, high-load conditions, the process depends on worm gear reducers, helical gearboxes, and electric motors to ensure that key components such as conveyors, crushers, and screening systems remain operational.
The challenge
In 2024, the plant’s main worm gear motor driving the feed line failed without warning. Positioned at the start of the process, the entire processing plant is dependent on the feed system.
The original builder of the plant was initially contacted but could not deliver a fast enough solution. With downtime escalating, Fortis urgently needed a UK gearbox supplier and engineering partner capable of delivering a replacement quickly, with improved durability for harsh operating conditions.
The solution
Fortis turned to Brown GearTech, relying on our reputation as a trusted OEM gearbox supplier and power transmission partner. We:
- Supplied and fitted a custom worm gear motor within 48 hours
- Engineered a stronger, more durable build with upgraded materials
- Improved sealing against dust, debris, and abrasive waste
- Introduced a cataloguing and spares strategy, giving Fortis clear visibility of every gearbox and motor on site
As Nichola Adshead, Sales Director at Brown Europe, explains
We looked at why the failure happened, how to make the replacement more robust, and what could prevent it happening again. That’s why we recommended cataloguing every gearbox and motor on site. It’s about solving the immediate problem quickly, but also strengthening operations for the future.
– Nichola Adshead, Sales Director at Brown Europe
Impact
- Production restored in under 48 hours
- More durable gearbox reduces breakdowns and extends service intervals
- Contingency planning ensures faster responses to future issues
- Improved reliability in demanding, abrasive conditions
“The team coordinated everything with real rigour. Their customer service was superb and they were very professional throughout the process.” Tim Palmer, General Manager, Fortis IBA
“Their customer service was superb…”
Why it matters
For plants like Fortis’s Ridham IBA Processing Facility, downtime isn’t an option. Our ability to deliver fast gearbox replacements, matched electric motors, and custom gearbox solutions makes Brown GearTech a trusted partner for OEMs, recycling plants, quarries, and mission-critical industries across the UK.
By moving quickly, strengthening designs, and helping customers build resilience, we support long-term operational reliability — not just short-term fixes.
Keep your plant running, without compromise.
If downtime isn’t an option, partner with Brown GearTech for rapid gearbox replacements, durable custom builds, and expert support that strengthens your operations for the long term.
Contact our engineering team today to discuss your gearbox and motor requirements.
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