Client Case Study · Precision Motion · Food & Beverage
Precision Under Pressure
How a leading American espresso machine manufacturer eliminated noise, improved reliability, and doubled their Helix Linear component volume ~ shot by shot.
"A machine designed to disappear beneath your counter still has to perform flawlessly above it. That's where component choice becomes everything."
01 — Background
A Machine Built Around What You Don't See
This American manufacturer designs and produces a full range of espresso machines, from countertop manual units to high-end super-automatics. Their flagship innovation is an under-counter espresso system: boilers and all mechanical components are concealed below the work surface, freeing up valuable counter space without sacrificing performance.
Now in its third year of production, this flagship machine uses a piston-driven brew mechanism which is a system where precision, repeatability, and silence are non-negotiable. At the heart of that mechanism: Helix Linear Inch Ball Screws.
With a roughly 50/50 split between domestic and international sales, the company is currently leaning into the U.S. market with a strong "Made in USA" positioning which is a competitive advantage that's only sharpened as global tariff pressures and supply chain instability reshape buyer decisions.
02 — The Challenge
When a Competitor's Component Started Making Noise
The company originally sourced ball screws from a competing supplier whose component included a travel stop feature. Over time, however, performance degraded: noise levels increased and operational consistency declined. That is unacceptable for a machine positioned at the premium end of the market.
The engineering team needed a replacement that could meet their exacting performance standards and integrate cleanly into their existing mechanical design. They turned to Helix Linear.
The Decision
After working with Helix during the design phase to nail down specifications and bearing interfaces, the client transitioned fully to Helix inch ball screws and hasn't looked back.
03 — Performance in the Field
Three Years of Quiet, Reliable Operation
Operating inside a commercial-grade espresso machine means surviving daily exposure to heat, vibration, moisture, and the oils. Helix ball screws have held up without issue.
- No contamination or performance degradation from coffee and oil exposure
- Smooth, quiet operation that meets the expectations of a premium client base
- Solid fit and bearing interface, attributed to close collaboration with Helix engineering during the original design phase
04 — Design Evolution
A Redesign That Doubles the Order
The most significant development from our recent engagement: the client has redesigned their machine to incorporate a dual-piston system, replacing the previous single-piston architecture.
The change was driven by noise and reliability issues in their earlier freewheeling lead screw configuration. The dual-piston design resolves those issues entirely and the natural outcome is that the machine now requires two Helix ball screws per unit instead of one.
- 2× Helix components per machine - effective order volume doubling going forward
- Same Specification - new piston uses existing Helix ball screw spec at a shorter cut length
- 0 Disruption - current inventory continues on existing spec until depleted, then transitions
The new design is finalized and orders are ready to begin. Future iterations may reduce the screw length further, which would bring additional material cost savings as well.
05 — Looking Forward
Building a Smarter Supply Partnership
Like many precision manufacturers managing a complex BOM, lead time predictability is a top concern. A recent order came in at approximately 12 weeks which is longer than anticipated. The client highlighted the need for better production planning visibility.
Their ask is straightforward: proactive communication when lead times shift, early enough to adjust their own production schedule accordingly.
To address this, Helix introduced our blanket order program during the visit. The structure is a natural fit: the client provides a rolling forecast, Helix builds to those scheduled releases, and product ships as needed. Payment per release rather than upfront keeps cash flow manageable on their end.
Next Step
The client has agreed to set up blanket / scheduled release orders beginning with their next order cycle. Benefits include improved pricing, predictable lead times, and simpler production planning on both sides.
Precision Starts with the Right Partner
Whether you're designing a new mechanism or re-evaluating a current component, our engineering team is ready to help you get the specification right from the start.
Talk to a Helix Engineer