CASE STUDY: Proco – Cylindrical Brush

The Challenge 

Proco, a leading manufacturer and supplier of machinery and equipment to the global tobacco industry, faced an ongoing operational issue within its production processes. During manufacturing, excess tobacco would accumulate around machine seals, leading to contamination and reduced efficiency. 

This buildup required frequent manual cleaning, forcing production stoppages and increasing downtime. Proco needed a reliable solution to maintain seal cleanliness without interrupting operations. 

The Solution

Cottam developed a specialised brush designed specifically to keep machine seals clean during production. This innovative brush works continuously to remove excess tobacco as it accumulates, preventing buildup before it becomes problematic. 

By integrating the brush into existing machinery, Proco was able to significantly extend production runs, reduce the need for manual intervention, and minimize downtime. The solution not only improved operational efficiency but also contributed to more consistent product quality. 

Our Process 

We worked closely with Proco to understand the specific challenges within their production environment. This included analysing how and where tobacco buildup occurred and identifying the key pain points affecting efficiency. 

Based on these insights, Cottam designed and engineered a brush tailored to the exact requirements of the machinery and operating conditions. Prototypes were tested and refined to ensure durability, effectiveness, and seamless integration. 

The collaborative approach ensured that the final product not only solved the immediate issue but also added long-term value to Proco’s operations. 

The results

The introduction of Cottam’s seal-cleaning brush delivered immediate, measurable improvements to Proco’s production operations. By preventing tobacco buildup, machines were able to run for longer periods without interruption, significantly reducing downtime.

With manual cleaning largely eliminated, operators could focus on maintaining productivity, leading to more consistent output and improved overall equipment efficiency. Reduced seal contamination also enhanced machine performance and product quality, while lowering maintenance costs.

As a result, Proco achieved longer production runs, increased throughput, and greater operational reliability.