ALWAY

Protected: Case Study – High Capacity Pie Conveyor

alwayadmin — Sun, 04 Jan 2026 13:00:44 +0000

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Case Study – Elevating Conveyors for a Chocolate Manufacturer

alwayadmin — Tue, 16 Dec 2025 11:23:27 +0000

Mobile Elevating Conveyors for a Global Chocolate Manufacturer

The challenge

A global chocolate manufacturer required a reliable and hygienic way to collect and transport rejected chocolate products for recycling. The solution needed to operate in a busy factory environment, support strict food safety standards, and align with the company’s commitment to sending no food waste to landfill. Flexibility across the site was also essential, allowing equipment to be redeployed as production demands changed.

The solution

Alway designed and manufactured a series of mobile elevating conveyors, engineered specifically for food handling applications. Each conveyor is fully food grade, robust in construction, and designed for ease of cleaning and maintenance.

The conveyors feature SEW motors and Intralox ThermoDrive belting, providing reliable performance while minimising product loss during transfer. Their mobile design allows operators to move the conveyors easily between production areas, giving the customer greater flexibility in how waste chocolate is collected and processed.

The result

The mobile elevating conveyors now play a key role in the customer’s waste handling and recycling process. By improving the collection and transport of rejected chocolate, the system helps reduce product wastage and supports the manufacturer’s no food waste to landfill objectives.

The ability to deploy the conveyors across multiple areas of the factory has improved operational efficiency and reduced downtime. Straightforward maintenance and durable construction ensure long-term performance in a demanding production environment.

Work with Alway

This project is one example of how Alway works alongside customers to develop engineering solutions that suit their operation, environment, and long-term objectives. From mobile conveying systems to food processing equipment, our team focuses on practical design, build quality, and ease of use.

For more information about our engineering solutions or to discuss your next project, contact our team directly at 01509 611 235 or by emailing enquiries@alway.co.uk

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Protected: Dough Conveyor Line

alwayadmin — Mon, 16 Jun 2025 09:42:55 +0000

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Introducing Alway Electrical

alwayadmin — Mon, 16 Jun 2025 08:00:00 +0000

Introducing Alway Electrical

We’re proud to introduce Alway Electrical, the latest addition to the growing Alway Group. Building on decades of engineering expertise at Alway Loughborough, this new division enhances our ability to deliver complete turnkey solutions to customers across a wide range of industries.

Alway Electrical provides a full suite of electrical integration services, including:

Design and Manufacture of Electrical Control Panels tailored to the needs of each project

Electrical Installations for machinery, production lines and facilities.

PLC and Automation Software Development, integrating smart, effecient control and monitoring systems

On-site Supervision and Support to ensure quality, safety, and project delivery

Testing and Inspection services to maintain compliance and system integrity

With over 30 years of hands-on experience, the Alway Electrical team combines practical know-how with technical expertise. From small-scale upgrades to large, complex integrations, Alway Electrical will bring efficiency, value, and reliability to every project.

The new division will be led by Dipak Jadav, who brings over three decades of electrical experience and a deep understanding of the industries we serve. A familiar face to many of our long-standing customers, suppliers, and colleagues, Dipak’s leadership will ensure a smooth and confident expansion of our services.

“I’m incredibly proud to lead Alway Electrical and build on the trust we’ve earned over the years,” says Dipak. “It’s exciting to be part of a group focused on delivering complete, high-quality solutions to our clients. I’m looking forward to this next chapter.“

This new division allows the Alway Group to offer our clients a truly integrated approach, covering mechanical and electrical engineering, automation, fabrication, and installation all under one roof.

The Alway Group now comprises:

Alway Loughborough – Fabrication, mechanical design, engineering, and machinery manufacturing

Alway Electrical – Electrical control systems, installations, and automation

Aqualine by Alway – Stainless steel solutions that cover everything from drainage and kerbing to bollards and bump rails

BagForm – Designers and manufacturers of VFFS forming sets for the packaging industry

By bringing these capabilities together, we can manage more of the project lifecycle in-house, resulting in better coordination, reduced lead times, and solutions that are built around our customers’ needs.

Whether you require complete system integration, electrical installations, or a trusted partner for complex engineering projects, Alway Electrical enhances our capability to continue to deliver at an industry-leading standard.

To learn more about Alway Electrical, follow the link below.

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Alway Celebrates 40 Years

alwayadmin — Wed, 28 May 2025 18:44:32 +0000

Alway Celebrates 40 Years

Established in 1985, Alway proudly marks its 40th year of trading in 2025, four decades of engineering excellence, innovation, and service. The milestone was recently celebrated in style with cake and a visit from the Mayor of Loughborough, Councillor Dr Julie Bradshaw MBE, accompanied by the Mayoress, Julie Ellerbeck. It was a special moment not only to look back at how far the business has come, but also to honour the people and partnerships that made it all possible.

Alway’s journey began in the 1980s in The Maltings, Sileby, with a small, dedicated team supporting local businesses, including Walkers Crisps.

In the 1990s, the company relocated to Barrow Upon Soar, setting the stage for future growth. It was during this time that Jason Larke, now Managing Director, joined the company. Alway expanded its offerings into various food sectors and even undertook international work, investing in advanced tools such as a spark erosion machine to meet evolving customer demands.

The 2000s saw a major transformation as Alway moved into a purpose-built facility in Loughborough, enabling it to support blue-chip companies and household names across the UK and beyond. This move was instrumental in scaling up both production capacity and technical capabilities.

In the 2010s, Alway’s reputation for design and engineering innovation continued to grow. They developed and installed direct feed systems for brands such as Walkers Crisps and Hotel Chocolat, further strengthening their position in the food manufacturing industry.

The 2020s marked a new era of diversification and expansion. Alway became a larger group of companies that includes:

BagForm – manufacturers of VFFS forming sets
Aqualine – specialists in designing, manufacturing and installing stainless steel drainage and kerbing solutions
CANALNTM – experts in tobacco recovery systems

With expanded manufacturing and office facilities, Alway now employs a team of over 30, including a full management structure, and continues to deliver cutting-edge engineering solutions. One such innovation is the HSP9000, a pioneering blue cheese piercing machine developed entirely in-house and successfully brought to market.

Alway’s 40-year story is a testament to consistent growth, adaptability, and engineering excellence. As they look to the future, the company remains committed to innovation, partnership, and delivering high-quality solutions to industries across the UK and beyond.

Here’s to the next 40 years of success!

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Case Study: Pizza Conveyor

alwayadmin — Tue, 08 Apr 2025 10:21:06 +0000

Pizza Conveyor

Custom Pizza Conveyor System with Integrated Diverter Unit

A leading UK-based pizza manufacturer approached Alway in early 2025 to design and build a bespoke conveyor system for their high-throughput production line. With growing demand and a need for greater flexibility in their packaging area, the client required a reliable solution that could handle a variety of pizza products with minimal downtime and maximum efficiency.

Our engineering team delivered a turnkey conveyor system tailored to suit the facility’s layout, product mix, and operational requirements.

Client Requirements

The client needed a robust and hygienic conveyor line that could:

Handle multiple sizes of pizzas
Accommodate a flexible packing process with automated routing to different stations.
Offer quick clean-down features to meet strict hygiene standards.
Integrate with existing systems and floor space constraints.

The Solution

Alway engineered a fully stainless steel conveyor system featuring:

Custom Diverter Unit: An automatic diverter to distribute products between multiple lanes, increasing packing line efficiency and allowing flexible routing to match product types or operational needs.
Modular Construction: Designed for future upgrades and ease of maintenance.
Compact Footprint: Layout tailored to fit the existing space while optimising flow and operator access.
Integrated Controls: Designed and installed by Alway’s in-house electrical team for seamless automation with existing line controls.

Intralox Belting Integration

The conveyor system was fitted with Intralox modular plastic belting to ensure top-tier reliability, hygiene, and performance. The use of Intralox belting provided:

Hygienic Design: Easy-to-clean, durable materials that meet food safety standards.
Precision Product Handling: Smooth movement for delicate pizza bases and toppings.
Reduced Downtime: Proven performance and long lifespan in food environments.

“Intralox belting has proven ideal for our pizza line projects. Its cleanability and long-term durability make it a great choice for food-grade applications—and their team was incredibly responsive and helpful from design through to delivery.” – Guy Satterthwaite, Lead Engineer for Alway.

We’re proud to partner with Intralox to deliver best-in-class conveying systems that meet the evolving needs of modern food production lines.

Results

Since installation, the system has:

Increased product throughput
Reduced manual handling across packing lines.
Enabled greater flexibility for the client’s expanding product range.
Delivered smooth, consistent performance with minimal maintenance.

Conclusion

The completed conveyor system has helped the client improve throughput, reduce manual handling, and maintain high hygiene standards while giving them greater flexibility for future growth.

Working with proven components like Intralox belting contributed to a reliable and efficient solution that integrates smoothly into daily operations.

For more information about our food processing conveyor solutions or to discuss your next project, contact our team directly at 01509 611 235 or by emailing enquiries@alway.co.uk

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Case Study: Pie Conveyor

alwayadmin — Thu, 06 Mar 2025 10:53:30 +0000

Pie Conveyor

Innovative Pie Food Processing Conveyor Delivered by Alway for Leading UK Household Pie Brand

At Alway, we take pride in delivering innovative, hygienic, and reliable conveyor solutions tailored to the specific needs of the food processing industry. Our latest project involved the design and manufacture of a pie conveyor for a well-known and trusted household pie brand in the United Kingdom.

A Tailored Solution for Pie Production Efficiency

This food processing conveyor was developed to enhance the efficiency and reliability of the customer’s production line, ensuring the seamless handling of pies. Understanding the stringent hygiene and operational requirements of the food sector, we designed this conveyor to meet the highest food safety standards, using food-grade components throughout the build.

High-Quality Materials and Trusted Components

The conveyor features:

- Intralox conveyor belting, a globally recognised name for its hygienic, durable, and easy-to-clean design, ideal for food production environments.
- SEW drive equipment, known for its reliability, energy efficiency, and low-maintenance operation, helping to keep production running smoothly.
- A stainless steel framework, designed for washdown environments, ensuring long-term durability and compliance with food hygiene regulations.

Designed for Hygiene and Ease of Maintenance

As with all food processing conveyors produced by Alway, this system was built with hygiene and ease of maintenance at its core. The design incorporates easy-to-access components for cleaning and maintenance, reducing downtime and ensuring the conveyor remains compliant with food safety standards throughout its lifecycle.

Supporting a Trusted British Pie Brand

This pie conveyor plays a key role in the production of some of the nation’s favourite pies. By delivering a solution that combines hygiene, performance, and reliability, Alway supports the brand’s commitment to producing high-quality products efficiently.

The Alway team completed this project around in under two weeks, providing our client with a fast turnaround time on a business-critical piece of equipment.

Your Partner for Food Processing Conveyor Solutions

At Alway, we specialise in delivering custom conveyor systems for food and beverage manufacturers across the UK. Whether you need a pie conveyor, a bakery line, or a bespoke handling system, our team has the expertise to design, manufacture, and install the right solution for your business.

For more information about our food processing conveyor solutions or to discuss your next project, contact our team directly at 01509 611 235 or by emailing enquiries@alway.co.uk

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Case Study: Bakery Conveyor Line

alwayadmin — Thu, 03 Oct 2024 07:11:25 +0000

Bakery Conveyor Line

Project Overview

Alway Loughborough, a leading engineering and fabrication business established in 1985, was tasked with designing, manufacturing, and installing a state-of-the-art bakery conveyor line for a well-established bakery. The project aimed to enhance the bakery’s operational efficiency, processing capability, and overall productivity in producing loaves of bread.

The Client

The client is a renowned bakery known for its family focus and passion for baking. With a strong market presence, they sought a solution to streamline their production process, accommodate increasing demand, and reduce maintenance downtime.

Project Scope

The conveyor line was required to extend over 270 metres in length and include a half-metre incline to facilitate elevation increase in the factory.

A future-proof, efficient, and robust solution was required to process up to 2000 loaves per hour, enabling the bakery to meet increasing demand while maintaining high quality. Furthermore, the conveying line needed to be easy to clean and maintain.

The project needed to be delivered at pace within a fast-paced construction schedule.

Our Solution

The conveyor line was meticulously designed to meet the bakery’s specific requirements, with a well-designed framework and leg design to accommodate the factory layout and incline. Tests and trials were conducted, including producing prototypes to ensure the final conveying solution met the project scope.

The conveyor incorporates removable sections to enhance maintenance efficiency, providing easy access for quick servicing. The robust framework ensures protection for critical components, contributing to the overall durability of the conveyor line.

Additionally, it features various operational enhancements, including brake units that guarantee precise placement of bread tins into the oven, a magnet conveyor to facilitate accurate distribution of dough into the bread tins with minimal wastage, and a diverter conveyor that optimises operational flexibility by managing which lines are in use.

Furthermore, particular focus was placed on the material specification, specifically in the plastics, bearings and belts used to ensure they could accommodate the heat dissipation requirements.

Design and Development Process

Collaboration and Layout Planning

Alway’s engineering team collaborated closely with the client to understand the specific layout requirements and operational needs. The design process included:

Site Assessment
Evaluating the existing bakery layout to provide a solution that would integrate seamlessly within the factory layout.

Concept & Trial
Develop a tailored solution that aligns with the bakery’s workflow and production goals. This was supported by fully operational prototypes.

Feedback Iteration
Incorporating client feedback at various design stages to ensure all specifications were met.

Key Features

Magnet Conveyor The magnet conveyor line was designed to hold tins in place precisely and ensure minimal wastage during dough distribution. This feature enhances the filling accuracy and optimises the use of raw materials. Diverter Conveyor

The diverter conveyor allows for the control of operational lines, providing operational flexibility. This flexibility minimises downtime, enabling the bakery to maintain production during servicing and repairs.

Heat Dissipation Alway incorporated heat-resistant materials and innovative belting designs to address the challenges posed by high-temperature environments. These features ensure effective heat dissipation, preserving the integrity of the bread and the conveyor system.

BluLub Side Guides

The BluLub side guides supplied by Oadby Plastics were chosen to future-proof the conveyor system by reducing the risk of high wear on bends. Their low-friction properties and exceptional durability provide long-term reliability, ensuring the line remains efficient and resilient to future operational demands.

Guy Satterhwaite, Lead Design Engineer for Alway, said, “This large-scale conveyor line project posed many challenges. Our goal was to provide the client with a future-proof, robust and efficient solution. The chassis and framework for the conveyor goes above and beyond the industry standards in terms of finish and strength, whilst the specified operating components are some of the best in the industry. The project’s successful completion was achieved through a collaborative team effort by everyone involved. I invested quality time working with the client and our manufacturing team to overcome challenges and further refine our solution.“

Installation and Commissioning

The installation of the conveyor line was executed within a tight timescale, reflecting Alway’s commitment to delivering industry-leading standards. Key steps included:

Site Preparation
Ensuring the bakery was ready for installation with minimal disruption to ongoing operations.

Installation
Our expert, “Safe Contractor” approved onsite team installed the conveyor system, integrating it with existing machinery safely and efficiently.

Testing
Comprehensive testing was conducted to validate the functionality and efficiency of the conveyor line before handover.

Reece Taylor, Divisional Operations Manager for Alway, said, “This project demonstrates Alway’s capability to provide small and large-scale solutions to a diverse range of industries. We are pleased with the client’s feedback on the quality and functionality of the bread tin conveyor.“

Conclusion

A Future Proof Efficient Bakery Conveyor Solution

The new conveyor line has successfully increased the bakery’s production capability to 2000 loaves per hour, meeting the growing output requirements without compromising quality.

With its robust framework, our tin conveyor provides superior protection for key components. Removable sections allow for quick maintenance, significantly reducing downtime.

Including diverter and mag conveyors have enhanced the bakery’s operational flexibility, enabling seamless transitions between production lines and reducing material wastage.

The successful delivery of this bakery conveyor line by Alway Loughborough is a testament to our design, engineering and manufacturing capabilities, which have drawn on the extensive knowledge and experience that have defined our company since its establishment in 1985. This project enhances the bakery’s operational efficiency and sets a new benchmark for future endeavours within the industry.

Follow the link below to get in touch with the Alway team.

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PPMA Success for Alway

alwayadmin — Mon, 30 Sep 2024 06:35:02 +0000

PPMA Success for ALway Group

Alway Loughborough has had another successful year at the PPMA show, exhibiting alongside our associated brands, BagForm International and Aqualine by Alway. We were also delighted to have Mick Sturgess, the Sales Director for Riley Automation, join us on Wednesday, showcasing his extensive knowledge and experience with the many visitors who joined us on our stand.

Mick Sturgess, Sales Director for Riley Automation, said, “It was a pleasure to meet the many industry professionals who visited this year’s PPMA Show and to exhibit alongside the fantastic teams at Alway, BagForm and Aqualine by Alway.“

On our stand, Alway showcased a selection of our latest engineering solutions, including a sieving conveyor to a vibrating conveyor. Our sister companies, BagForm and Aqualine by Alway, were also present on the stand, with BagForm displaying the latest in VFFS forming set and tube closer solutions and Aqualine by Alway demonstrating their high-quality food grade range of drainage, kerbing and bump rail.

Reece Taylor, Divisional Operations Manager for Alway Loughborough, said, “This year’s PPMA Show was even better than the last; we are pleased with not only the quantity but the quality of leads we have gained from exhibiting at this year’s show. The team is looking forward to exhibiting at next year’s show and celebrating our 40th anniversary.“

Alway would like to thank everyone who visited us on our stand and the team at Automate UK for putting on a fantastic PPMA Show.

We look forward to connecting with everyone over the coming weeks to see how we can help you with your next project.

If you missed us at the PPMA Show, you can contact us by clicking the links below.

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PPMA Preview 2024

alwayadmin — Mon, 16 Sep 2024 12:03:59 +0000

Join us at the ppma show

Alway will be attending the PPMA Show (Processing and Packaging Machinery Association) held at the Birmingham NEC from the 24th to the 26th of September.

The PPMA Show is the UK’s leading processing & packaging machinery event with 30 years of history, welcoming 7,000 visitors, over 300 stands and access to 70,000 industry contacts.

We will be exhibiting on stand B74, where we will be showcasing a selection of our range of engineering solutions.
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To learn more about our extensive range of products, services, and solutions that have been developed since 1985, and to speak to a member of our team at the PPMA Show, register for your free ticket using the link below.

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