A food manufacturing facility required an urgent engineering response after the agitator shaft inside a 35,000-litre chocolate mixing tank failed, taking a critical production vessel out of service.
Industry: Food Manufacturing
Tank Type: Chocolate mixing tank
Tank Capacity: 35,000 litres
Access: Rope access
Environment: Confined space
The problem
A fault with the tank’s heated water jacket caused the chocolate to cool and begin to solidify. As resistance increased, the agitator continued to rotate until the mixing shaft eventually sheared.
Key issues identified:
- Increasing resistance overloaded the agitator
- The mixing shaft sheared inside the vessel
- A critical production tank was taken out of service
- Loss of heating caused the chocolate to solidify
- Repair access was only possible from inside the confined space
The breakdown created an urgent requirement for a safe and practical repair that would minimise production downtime while avoiding the additional time and disruption associated with installing temporary scaffolding.
Our Approach
Following an emergency inspection and engineering assessment, a bespoke flanged repair was developed alongside a controlled rope access installation plan.
Specialist engineers trained in both rope access and confined-space working carried out the repair from within the vessel. This approach removed the need for temporary scaffolding and enabled the work to be completed efficiently in a difficult-to-access location.
Step 1
Inspection & Engineering Assessment
- Inspected the failed agitator shaft and surrounding components
- Assessed the confined-space access and rescue requirements
- Confirmed the damaged shaft section to be removed
Step 2
Bespoke Repair Design & Fabrication
- Designed a bespoke flanged repair collar
- Precision-fabricated the component to suit the existing shaft arrangement
- Prepared the repair assembly for on-site welding and installation
Step 3
Rope Access Installation & Recommissioning
- Removal of the damaged shaft section
- Installed the bespoke repair
- Realigned and recommissioned the agitator
- Completed final inspection and a food-grade wet clean before handover
The Results
The repair enabled the production facility to restore the critical mixing vessel to operation without a prolonged shutdown.
- Rapid restoration of production
- Minimal downtime
- No requirement for temporary scaffolding
- Successful agitator alignment and recommissioning
- Food-grade cleaning prior to handover
Key Benefits
- Rapid recovery of a critical production asset
- Reduced disruption to manufacturing operations
- Avoided the additional time and cost associated with temporary access structures
- Specialist rope access and confined-space working
- Bespoke engineering tailored to the existing equipment
- Controlled and hygienic return to production
Why Specialist Tank Repair Matters
Failures within large process vessels can present a combination of engineering, access, safety and production challenges. This project demonstrates how mechanical engineering, bespoke fabrication, rope access and confined-space expertise can be combined to deliver an efficient repair solution.
- Safe access to difficult internal repair locations
- Repair strategies designed around existing equipment
- Reduced reliance on temporary scaffolding or access structures
- Efficient welding, inspection and recommissioning
- A controlled and hygienic return to production
Need Emergency Engineering Support?
If your tank, silo or process equipment has suffered a mechanical failure, our specialist engineering team can assess the problem and develop a safe, practical repair solution.