Banelec, the Brierley Hill-based electrical control systems specialist, has successfully completed a major £500,000 contract for a fan case lifter designed for a global aerospace OEM, marking another significant milestone for the West Midlands manufacturer.
The project saw Banelec develop and deliver assisted lifting equipment created to solve repetitive health and safety strain injuries associated with handling large, heavy fan case units during aerospace manufacturing. The bespoke system enables operators to lift, lower and rotate the components safely and precisely, reducing physical strain on engineers while improving handling accuracy on the production line.
The contract win underlines Banelec’s growing reputation as a trusted behind-the-scenes engineering partner for some of the world’s biggest industrial brands. From its base in the Black Country, the business has built its name over more than two decades by designing and manufacturing bespoke electrical control and automation systems that help customers improve safety, productivity and operational performance.
Banelec lands £500,000 aerospace order for engine fan case lifting system
Managing director Dean Banner said the successful completion of the project demonstrated the value of combining practical engineering expertise with a clear understanding of customers’ workplace challenges.
“This was a major contract win for Banelec and one we are extremely proud to have delivered successfully,” he said. “The brief was not simply to move a large aerospace component from one position to another. The real challenge was to create a solution that directly addressed repetitive strain and manual handling risks for the people working on and around the fan case every day.”
“By designing assisted lifting equipment that can raise, lower and rotate the unit in a controlled and precise way, we have helped the customer create a much safer working environment while also improving consistency and efficiency in the process.”
Banelec worked closely with the customer to understand the demands of the application before designing a system based around three electric-powered jacks positioned equidistantly around the fan case. Each jack is controlled through its own electrical control panel, with all three operating in unison to manipulate the load safely in line with operator requirements. A radio control system provides a user-friendly interface, allowing engineers to control movement smoothly and with confidence.
For the aerospace customer, the system represented a step-change in both operator safety and process capability. Fan case units are critical aircraft engine components, but their size and weight can make them difficult to handle during construction and finishing operations. The ability to reposition the unit safely at different heights reduces the physical demands placed on workers and lowers the risk of damage to valuable components.
Banner said the contract reflected Banelec’s wider approach to engineering-led problem solving.
“At Banelec, we are at our best when we are solving real operational problems,” he said. “This project is a strong example of how smart electrical control and automation can make manufacturing not only more productive, but also safer and more sustainable. That is exactly where industry is heading, and it is where we add the greatest value.”
“To secure and complete a £500,000 order for a major global aerospace OEM is a significant achievement for our team in Brierley Hill. It shows that specialist engineering expertise developed here in the West Midlands can compete with the very best and deliver on some of the most demanding projects in global manufacturing.”
The installation was completed efficiently and integrated into the customer’s existing flow line with minimal disruption. Extensive testing was then carried out to assess lifting capacity, durability, reliability and control accuracy under a range of operating conditions.
Banelec said the success of the project has helped establish a new benchmark for safe fan case handling in aerospace production and reinforces the company’s credentials in delivering bespoke systems for high-specification industrial environments.
Known for its work across automation, hazardous area controls, robotics, Industry 4.0 applications and electrical control systems, Banelec has supplied solutions to major names including Rolls-Royce, Jaguar Land Rover, GKN, Chevron, BP and Aibel. The latest aerospace contract adds further weight to its claim of being one of the sector’s best-kept secrets.
With demand growing for smarter and safer manufacturing solutions, the company believes projects such as the fan case lifter highlight how UK engineering firms can play a critical role in helping global manufacturers modernise production while protecting their workforce. For more information, visit https://www.banelec.com/
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