Transformers & Rectifiers

Transformers & Rectifiers (T&R) is a UK-based manufacturer of heavy transformers and rectifiers. In their existing factory in Guildford, they produce complex units weighing up to 23 tons. To move these safely and efficiently without major modifications to the building, a new approach was required.

Impact

Transformers up to 23 tons are moved in one piece, without cranes or dismantling.

Up to two days saved per test cycle.

Transport, testing, and production now run in one continuous flow.

Heavy units can be easily moved between different areas.

The challenge

Transformers & Rectifiers faced a clear limitation in their existing facility. The overhead crane had a capacity of 15 tons, while their transformers can weigh up to 23 tons. Upgrading the crane or modifying the building was not a viable option due to structural limitations and available space.

As a result, transformers could not be moved as a whole. Units had to be dismantled and drained of oil before transport, then reassembled afterward — and often dismantled again later in the process.

This approach was time-consuming, costly, and prone to errors. It disrupted the production flow and limited operational flexibility across the factory.

“We were building transformers up to 23 tons, but our infrastructure was holding us back. Dismantling products just to move them cost us a huge amount of time and money and disrupted the entire production process.”

Mark Holtman – Operations Director

Our approach

In close collaboration with T&R, Aerofilm Systems developed a solution based on air caster technology, fully tailored to the existing factory environment.

The selected solution consisted of two Air planks, capable of handling loads up to 23 tons. This allows transformers to be moved smoothly and safely across the factory floor — without cranes or disassembly.

A key challenge was the condition of the existing floor, which was not originally suitable for air caster transport. Together with T&R, the floor was assessed and adapted where necessary to ensure optimal performance of the system.

Throughout the project, Aerofilm acted not just as a supplier, but as a partner. From engineering to on-site implementation, close collaboration ensured the solution was reliable and fully integrated into daily operations.

The result

The implementation of the air caster system fully resolved a complex internal logistics challenge.

Transformers can now be moved in one continuous motion through the factory, without additional handling or interruptions. This has led to significant time savings, reduced costs, and a more stable production process.

Production flow has improved, and internal transport is now a seamless part of operations. At the same time, flexibility has increased significantly, enabling T&R to handle larger and heavier products within the same facility.

This case shows how a practical and innovative solution can overcome existing limitations — without major changes to infrastructure.