Prototyping, in 10 days…
A client came to us with a problem that needed a solution urgently. They had a brand new custom machine they’d designed to fill bags of coffee beans from a large dispenser – a key part of this machine was a system to blow nitrogen into the bags of coffee – as it displaces air, and acts as a preservative (with nitrogen in the bag, the coffee would stay fresh for 6 months longer).
The machine had already been installed on site at the Dualit Factory, but the nitrogen gas had to be added to the coffee bags manually by the operator. We were asked if there was any way we could design, make and install a solution to do it automatically within 10 days, and we did.
Designing a prototype PBC board
After visiting the Dualit Factory and the coffee bagging machine, we got to work on the PCB design. We drew then modelled this digitally, in fact you can check out our PCB board below!
Click and drag to view the PCB Components
PCB etching & drilling in-house
By handling PCB etching in-house, we eliminate the delays of outsourcing, giving us full control over quality and turnaround times. This means faster production, reduced risks of errors, and the ability to meet tight deadlines without compromise. For customers working to urgent schedules, our streamlined process ensures prototypes are ready in as little as 10 days—keeping your projects on track and your business moving forward.
We have facilities here that:
- Print a circuit board track design onto clear acetate
- Expose this design on an ultraviolet light box
- This photo sensitive circuit board then goes into a developing solution
- Place board into an acid etch tank, so all of the copper on the board is dissolved except the tracks
- Tin plate, and drill out the board – giving you a fully usable circuit board – In about an hour!
Mechanical design and software
Building a PCB is more than connecting components—it’s about integrating precision and functionality into a complete system. Our process includes mechanical design to ensure the PCB fits seamlessly into its intended application, as well as CNC machining for accurate fabrication and clean, reliable results. Combined with embedded software development, we create PCBs that are fully optimised for their operational environment, delivering performance and reliability in every project.
The finished system
So we sent it to be installed, and now their machine is running flawlessly. We understand that , especially in factory settings, a machine that isn’t functioning properly can cause all operations to stop! Luckily we got this thing up and running, and now we really could do with a coffee…
At Winter & Smith, we thrive on solving complex challenges and turning outdated tech into reliable, future-proof solutions. Whether it’s breathing new life into essential machinery or designing innovative systems from scratch, we’re here to keep your operations running smoothly.
