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How a Wisconsin Beverage Equipment Manufacturer Solved Labeling Accuracy Problems by Improving Shaft Assembly Quality
Customer Overview
Ryan Mitchell leads an engineering team at a beverage packaging equipment manufacturer based in Wisconsin. The company designs and builds rotary labeling systems used by beverage producers throughout North America.
In late 2024, the team began upgrading one of its high-speed labeling machines to meet increasing customer demands for production efficiency and labeling precision.
The Challenge
The project initially encountered an unexpected obstacle.
Several welded flange shaft assemblies supplied by an existing vendor failed to meet the required rotational accuracy after welding. During testing, engineers observed excessive runout that became increasingly noticeable at higher operating speeds.
Although the deviation appeared minor during inspection, its impact on machine performance was significant.
The resulting vibration led to:
- Premature bearing wear
- Increased maintenance requirements
- Inconsistent label placement
- Reduced machine stability at full production speeds
For beverage manufacturers operating around the clock, even small positioning errors could result in rejected products, production interruptions, and unnecessary operating costs.
Ryan's team needed a more reliable shaft assembly solution that could maintain strict concentricity requirements while withstanding continuous industrial use.
Searching for a Better Manufacturing Partner
After evaluating several suppliers, the engineering team focused on finding a manufacturer with stronger welding control and machining capabilities.
The key requirements included:
- Accurate flange-to-shaft alignment
- Consistent concentricity after welding
- Reliable dimensional inspection
- Repeatable quality across production batches
- Short lead times for prototype validation
Rather than simply sourcing another component supplier, the team was looking for a manufacturing partner capable of understanding the functional requirements of rotating equipment.
The Solution
Working closely with the customer’s engineering department, a revised manufacturing process was developed for the welded flange shaft assemblies.
Several improvements were introduced throughout production:
Precision Machining Before Welding
Critical shaft and flange dimensions were machined to tighter tolerances before assembly, providing a more stable foundation for the welding process.
Controlled Welding Procedures
Specialized fixturing was used to maintain alignment during welding and minimize thermal distortion.
Post-Weld Machining
After welding, critical surfaces underwent secondary machining operations to restore dimensional accuracy and ensure proper concentricity.
Enhanced Quality Verification
Each assembly was inspected using precision measuring equipment to verify runout, alignment, and dimensional compliance before shipment.
The Results
Following installation and testing, the upgraded shaft assemblies delivered measurable improvements across the labeling system.
Within the first months of operation, Ryan's team reported:
- Significantly lower rotational vibration
- Improved labeling consistency at high operating speeds
- Reduced bearing replacement frequency
- Smoother machine performance during extended production runs
- Greater confidence in long-term equipment reliability
Most importantly, the machine was able to maintain accurate label positioning even during peak production conditions.
The engineering team successfully completed the upgrade project and moved forward with production deployment.
Customer Feedback
"The improvement was noticeable immediately during testing. Machine vibration dropped substantially, and label placement became much more consistent. The assemblies met the tolerances we needed and helped us complete the upgrade with confidence."
Ryan Mitchell
Engineering Manager
Wisconsin, USA