Step Inside Unit 2
Welcome to Unit 2, home to PECO Productions' track and wagon assembly in Beer, Devon. This is where turnouts are built and tested, wagons are sprayed and printed, and the kits, switches and accessories that go into your layout are packed and prepared for dispatch.
Below is a walk-through of each of the six benches and departments inside Unit 2, and what goes on at every stage. If you'd like to see it in person, you can book a guided PECO factory tour or browse our full range of tours and experiences.
Turnout Assembly
The turnout assembly line is where PECO's points are built and tested. Experienced operatives fit the point blade assembly to each turnout. The point blade is the moving part of a turnout that guides trains onto different tracks, so its alignment and finish are critical to reliable running.
Every assembled unit then goes through a three-stage inspection: electrical testing with a dedicated test box to verify conductivity, an operational test with a locomotive run-through to confirm smooth movement, and a visual check for overall quality. Passed turnouts are packed into clear sleeves with an insert card identifying the type, then sent to the finished goods store for distribution.
The range built on this line covers C100, C83, C75, C70, C80 and the specialist C55, alongside PECO's TT range. The C75B/H, known as bullhead rail, was the standard across the British network until flat bottom rails took over around 1960, and it's still produced here today. A semi-automatic curving tool shapes the point blades to the correct curvature for each turnout type, contributing to the reliability of the finished product.
- Ranges produced
- C100, C83, C75, C75B/H, C70, C80, C55, TT
- Inspection
- Electrical test box, locomotive run-through, visual check
- Packed as
- Clear sleeve with type-identifying insert card
Large Scale Turnout Assembly
Large scale turnouts are built on the points bench, where rails are inserted into the plastic mouldings and the point blades fitted by hand. Spot welders are then used to weld the wire in place, a process known as pelleting, securing the assembly and ensuring a durable connection between the components.
Each completed turnout is visually inspected and electrically tested, then a locomotive is run back and forth across it several times. This dynamic test confirms the turnout performs reliably under real-world conditions before it's packed and sent to the finished goods store.
Wagon Printing and Assembly
Wagons start their journey in the spray booth, where coatings are applied by the spray team using spray guns. They're then left for a drying period, allowing the coatings to set and adhere properly. This phase is essential to the durability of the finished wagon.
From there they move to the print bench, where ink jet printers apply the livery designs. Prints range from a simple two-letter white print with small text through to detailed multi-colour artwork. All liveries are sourced by PECO's innovations team, who also create the custom artwork required for production.
Once printed, wagons are assembled and placed on a test track to confirm the wheels run freely and smoothly. A final visual inspection follows, with any imperfections addressed before the wagons are packed and sent to the finished goods store for distribution.
Packing Department
The packing department prepares the accessories that bring a model layout to life. Every layout is different, and the range packed here is designed to suit a wide variety of scales, preferences and experience levels.
A key part of the work is packing switches and switch housing units, the components that let modellers control the movement of trains and the routing of power around their layouts. The team also packs PECO kits and accessories, including miniature buildings and finely crafted figurines that add detail and realism to a finished scene.
The department also assembles and packs PECO's starter set unit trackage systems, available in 00, N and 009 gauges. These sets provide an accessible entry point for newcomers to the hobby, while remaining useful to experienced modellers expanding their layouts.
- Items packed
- Switches, switch housing units, PECO kits, accessories, starter set trackage
- Gauges covered
- 00, N, 009
Odds Bench
The odds bench handles two important jobs. The first is managing the switches in the PECO Lectrics range, the components that act as the nerve centre of power distribution on a model railway. These switches let modellers change the direction of trains and activate different sections of track with precision.
The second job is housing the 00 and NG joiner fitting machines, which stamp the rail joiners onto the rail itself. The 00 machine handles standard gauge, the NG machine handles narrow gauge. The accuracy of this stamp matters: a secure, well-formed join keeps the rails stable, minimises disruption to running trains, and contributes directly to the overall reliability of a layout.
Welding Department
The welding department uses spot welders to place welding wire across the full turnout range: C100, C75, 75B/H, C83, C70, C80, C55 and the newer TT range. Each turnout calls for a specific welding approach, and the team builds to the relevant specification for every one.
Three welding styles are produced here: Insulfrog, Electrofrog and Unifrog. The variety exists because different turnouts and different layout wiring approaches call for different electrical behaviours at the frog (the point where two rails cross). Each style is tailored to suit a particular design.
Welding and point assembly work in close coordination. The two teams exchange components and specifications constantly, and that ongoing communication is essential to keeping production moving and quality consistent across every turnout that leaves the building.
- Welding styles
- Insulfrog, Electrofrog, Unifrog
- Ranges welded
- C100, C75, 75B/H, C83, C70, C80, C55, TT