Fixing the heart of Pyramid Tea Bag production
Reverse engineering circuit boards without drawings (it happens)
When customers supply circuit boards without schematics, we follow a detailed process to recreate and improve the design.
- First, we carefully dismantle the board, identifying and storing all components. The bare board is scanned to create accurate top and bottom images, and for multi-layer boards, the inner layers are exposed using specialised techniques.
- Using these scans, we trace visible tracks and rebuild the circuit digitally in our PCB design software, mapping components and connections layer by layer. This results in a functional but messy schematic, which we then refine into a clear and logical design.
- With a clean schematic and board layout, we identify outdated components for replacement and finalise the design for manufacturing.
This ensures a reliable, modern replacement board, even when no original documentation exists.
Our process
- Dissecting the board
We carefully disassembled the faulty controller, mapping each component and reverse-engineering the circuitry to understand its function without any original schematics.
- Streamlining the design
Our team reimagined the circuit layout, replacing outdated and costly parts with modern, efficient alternatives, improving reliability and reducing production costs.
- Delivering the upgrade
The newly designed controller was built, tested, and installed, ensuring the tea bag machines ran smoother than ever.
The new and improved controller
The upgraded controller not only restored full operational efficiency but also offered improved performance metrics, with enhanced durability and simplified maintenance. It’s a future-proofed solution designed to meet the rigorous demands of high-speed tea bag production machinery.
This is how complicated machinery can get, especially in the food and drink industry. Making your controllers as efficient as possible ensures your business stays streamlined. Need more circuit boards? We’ve already made one, and we can make as many as you require.
Why reverse engineer?
For tech-driven industries relying on bespoke or outdated systems, reverse engineering is often the most practical path to innovation. It bridges the gap between legacy technology and modern performance, extending the life of critical machinery while introducing new efficiencies.
At Winter & Smith, we thrive on solving complex challenges and turning outdated tech into reliable, future-proof solutions.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.
