Precision levelling adjusters explained
Uneven floors, vibration and heavy loads can throw machines out of alignment, leading to wear and poor performance. Precision levelling adjusters provide the fine height and angle control needed to set machines up correctly and keep them stable. By ensuring even load distribution and secure alignment, they reduce stress on components, cut downtime and help extend the life of the equipment.
This guide explains the fundamentals of precision levelling components. We’ll explore the key types of adjuster components, and show how to choose the right solution for your specific application. We’ll cover:
What is precision levelling and alignment?
Types of levelling adjuster components
Choosing the right precision levelling adjuster
Applications and uses
What is precision levelling and alignment?
Precision levelling and alignment are basic but essential engineering tasks. They ensure that machinery and structural parts are set in the correct geometric position relative to a reference plane or axis. When done properly, loads are distributed evenly and moving forces are transferred without causing excess vibration, wear or stress. This helps equipment run smoothly, reduces maintenance needs and prolongs service life.
Levelling refers to the process of adjusting a surface or component so that it is truly horizontal—or in some cases inclined to a specified datum plane—within prescribed tolerances. Achieving this involves measuring deviations from a reference plane and correcting them so that gravitational loads are distributed uniformly. Accurate levelling minimises bending stresses in frames and foundations, reduces bearing loads, and prevents distortion of machine bases.
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Alignment deals with positioning components so that their geometric centres, axes, or reference surfaces coincide with design specifications. In rotating machinery, even slight angular or offset misalignment between shafts can lead to vibration, heat build-up in bearings, premature wear on seals, and a shorter service life. Alignment is usually checked in two directions:
● Horizontal alignment, which ensures that components share a common horizontal centreline.
● Vertical alignment, which verifies that components lie in the correct vertical position relative to each other or to a datum plane.
Both levelling and alignment are interdependent. A machine installed on an uneven foundation cannot maintain precise shaft alignment under load; conversely, a well-levelled base may still produce poor performance if rotating or linear components are misaligned.
These processes are executed using advanced instruments such as precision electronic or laser levels, optical transits, laser shaft-alignment systems, and high-resolution dial indicators. These tools enable measurement and correction down to sub-millimetre—or even micron-level—tolerances, which is essential for high-speed rotating equipment, precision manufacturing systems, and load-critical structural assemblies.
In essence, precision levelling and alignment establish the geometric integrity of an installation. By providing a stable and properly oriented foundation and ensuring that all interacting components are correctly positioned, they enhance operational efficiency, extend equipment life, and reduce the risk of unplanned downtime or catastrophic failure.
Types of precision adjuster components
No single levelling solution suits every situation. Some machines need simple height correction, others demand precise angular adjustment or vibration control. The following component types highlight the most common options and where they perform best.
Ball shim levellers
Also known as levelling shims or precision shims, are designed to compensate for uneven mounting surfaces, offering a maximum tilt adjustment of 4°. They provide reliable, repeatable precision for maintaining vertical alignment in demanding applications.
Each precision shim features a fine-threaded mounting bolt, a threaded base nut, and an end-stop, enabling accurate adjustment and easy re-adjustment with a hook spanner. These levelling shims are quick to install and suitable for static and dynamic heavy-load conditions. Stainless steel, zinc plated steel.
Precision adjusters – tilt head
Tilt head precision levelling adjusters provide accurate angular adjustment for positioning and calibrating components. The tilt mechanism allows fine control of the mounting angle, making them suitable for applications where precise alignment is essential.
Designed for use in limited space, they hold their position securely even when exposed to vibration, external forces, or temperature changes. Steel or stainless steel.
Precision adjusters
Precision adjusters provide fine control for accurate placement, alignment, and calibration of components.
They are suitable for compact installations and allow small, precise height changes for consistent performance and repeatable results. Once adjusted, they stay in position even when exposed to vibration, external forces, or changes in temperature. Stainless steel or steel.
Spherical seat washers
Spherical seat washers feature a slightly convex or concave surface that allows them to compensate for misalignment between mating surfaces when used with nuts or bolts. This ensures a secure connection and protects both fasteners and components from undue stress.
By evenly distributing loads and pressures, spherical seat washers reduce stress concentrations caused by surface irregularities, enhancing assembly stability, reliability, and longevity.
Their superior load-bearing capacity makes them ideal for applications involving heavy loads or dynamic stresses. Made of steel.
Other considerations
Levelling feet – adjustable
Levelling feet are used to support cabinets, equipment enclosures, and free-standing electrical units so they remain level on uneven floors. They improve stability and help control vibration, shock, and tilting for safe and consistent operation.
Available in a variety of materials, including metal, nylon, and rubber, these components are adaptable to a wide range of environments and requirements. The range includes solutions for appliances, office and retail furniture, machinery, and other industrial or commercial applications, allowing you to select the most suitable option for your specific needs.
To find out more, explore our Guide to adjustable levelling feet. You should also see our Guide to levelling feet.
Choosing the right precision levelling adjuster
Selecting the correct levelling or alignment component is critical to achieving stability, precision, and long-term reliability in your equipment or assembly.
|
Product |
Ideal use case |
Key features |
Common industries |
|
Ball shim levellers |
Compensate for uneven mounting surfaces and maintain vertical alignment |
-Up to 4° tilt adjustment -Fine-threaded bolt & base nut for precise adjustment -Quick installation for static & dynamic heavy loads |
-Engines -Industrial machinery -Laboratory equipment -Defence manufacturing |
|
Precision adjusters – tilt head |
Provide angular adjustment for precise positioning and calibration |
-Integrated tilt mechanism for fine angular control -Maintains set position under vibration and temperature changes -Ideal for space-constrained installations |
-Electronics -Robotics -Machine tools -Medical equipment |
|
Precision adjusters |
Offer incremental height adjustment for precise alignment |
-Fine-tuning control for accurate placement and repeatable results -Stable under vibration, external forces, and thermal variation |
-Electronics -Robotics -Machine tools -Medical devices |
|
Levelling spacers |
Bridge gaps where standard adjustment isn’t sufficient; ensure proper clearance and load distribution |
-Help align components that aren’t perfectly perpendicular or parallel -Distribute loads evenly, reducing stress and wear -Valuable in vibration-prone, heavy-load applications |
-Automotive systems -Industrial machinery -Electrical equipment |
|
Spherical seat washers |
Compensate for misalignment between mating surfaces when using bolts or nuts |
-Convex/concave surface ensures secure, stress-free connections -Distributes loads uniformly, reducing stress concentrations -Enhances assembly reliability under heavy or dynamic loads |
Machinery- -Structural assemblies -Automotive systems |
Key selection factors
● Load capacity: Ensure the component supports static and dynamic loads without deformation
● Adjustment requirements: Match the adjustment range—height or angular—to the installation needs
● Environmental conditions: Use stainless steel for corrosive or hygienic environments; steel or zinc-plated steel for general industrial use
● Vibration and stability: In applications with vibration or heavy loads, use components that keep their setting and spread the load evenly
● Space constraints: Compact designs like precision adjusters or tilt-head adjusters are ideal for tight installation spaces
Applications and uses
The table in the previous section shows at a glance the components and their common industries. Here we take a deeper dive into how each product type is used in applications.
Ball shim levellers
Provide tilt adjustment (up to 4°) and vertical alignment for machinery installed on uneven floors or frames.
● Packaging machinery: levelling conveyors, sealing units, and fillers for stable and precise operation
● Robotics: stabilising robot pedestals and automated cells on imperfect floors
● Woodworking & furniture production: levelling CNC routers, saw tables, edge-banders to prevent frame twist and ensure cut accuracy
● Metalworking and machine tools: used to support presses, stamping machines, lathes, and milling machines to ensure proper load transfer
● Construction and structural assemblies: used for setting up cranes, gantries, bridge jigs, and other heavy equipment on uneven ground
● Food and beverage processing: used to provide stable, hygienic support for mixers, packaging lines, and weigh-scale unit
Precision adjusters – tilt head
Made for precise angular adjustment and used where equipment needs calibration or positioning in more than one axis.
● Packaging machinery: used to align label applicators, print-and-apply heads, camera inspection systems, and quality-control modules
● Robotics and automation: calibrating vision sensors, scanning heads, or EOAT fixtures for repeatable multi-axis positioning
● Medical and laboratory devices: fine-tuning the alignment of imaging optics, microscopes, and dispensing heads
● Electronics and semiconductor: adjusting pick-and-place feeders and wafer-handling modules
● Aerospace assembly and testing: aligning inspection jigs, non-destructive testing devices, or calibration rigs
Precision adjusters
Provide incremental height adjustment where repeatable, stable levelling is required.
● Robotics cells: levelling robot pedestals, jigs, or calibration tables
● Metalworking and machine tools: adjusting bed levels on lathes, milling machines, or surface grinders
● Woodworking: used to keep CNC router beds, in-feed and out-feed tables, and saw fences at the correct height
● Electronics assembly and test: used to keep instrument benches, PCB testing stations, and clean-room fixtures stable
● Automotive production lines: used to level welding jigs, test rigs, and handling stations for consistent, repeatable results
Levelling spacers
Levelling spacers provide fixed clearance or standoff and help spread loads where direct mounting is not suitable.
● Provide accurate clearance or standoff and help spread loads where direct mounting is not suitable
● Packaging machinery: used to create consistent gaps in modular frames, conveyor supports, and adjustable guides
● Electronics and electrical: used to provide insulated spacing for PCB assemblies, wiring harnesses, and control cabinets
● Aerospace and defence: used to achieve precise standoff and distribute loads in bolted joints for structural components
● Fixtures and jigs: used to maintain consistent offsets in toolholding or inspection fixtures
● Renewable energy installations: used in solar-panel mounts and wind-turbine fixtures to maintain alignment and distribute loads
Spherical seat washers
Spherical seat washers correct misalignment in bolted joints, reduce stress on the connection, and keep fastenings secure and stable.
● Robotics and heavy automation: used to secure robot bases, gantry frames, and other moving support structures
● Industrial machinery: used to protect bolts in presses, pumps, compressors, and equipment exposed to vibration
● Construction and structural steelwork: used in crane supports, lifting frames, bridge assemblies, and prefabricated modules
● Transportation and automotive: improving fastener integrity in test rigs, chassis assembly stations, and lifting devices
● Marine and offshore applications: maintaining secure bolted joints in platforms, winches, and heavy-duty deck equipment
Depending on your application, you might also find it helpful to see our guide, Types of levers and handles in industrial machinery.
Download free CADs
Free CADs are available for most solutions, which you can download. If you’re not quite sure which levelling component will work best for your application, our experts are always happy to advise you. Whatever your requirements, you can depend on fast dispatch.
Download free CADs
Questions?
Email us at sales@essentracomponents.co.uk or speak to one of our experts for further information on the ideal solution for your application at 0345 528 0474.