Gearing up: services to enhance reliability and productivity
Improve gear unit condition and performance
Responsible for driving the production process at exactly the right speed and power, your business is totally dependent on the gear unit. It must operate efficiently and require minimal downtime. However, it is often the piece of plant equipment that is pushed to the limit of its capacity and subject to the most extreme wear and tear over many years. So you need high-quality and high-value solutions and services.
Our experienced gear specialists ensure you get optimal equipment availability and uninterrupted production. Maintenance costs are also more predictable and we share knowledge with maintenance staff, helping to keep your gear unit in top condition at all times.
We offer a complete range of gear overhaul and repair activities for all parts, including rotating parts, bearings, and designed components. This includes:
- Dismantling parts and evaluating their health
- Repairing and replacing parts
- Assembling and function testing
Get a gear inspectionEVERY YEAR
or after 1,000, 6,000, and 12,000 running hours
Smooth gear unit start-up
Installing gears is one of our core areas of expertise, and we assist with all aspects of installation and start-up of new gears and gear replacements.
In addition to technical know-how, our service engineers can advise you on-site about achieving a reliable operation and we can train employees while commissioning. Together, we can design tailor-made installation and commissioning plans to suit your specific needs and ensure a smooth gear unit start-up.
Keep the risk of gear failure small
Significantly reduce the risk of a breakdown and loss of production: use our gear inspection services to determine the status and condition of your gear unit.
Many of our services can be performed during normal operation, including condition-based preventative maintenance and root cause analysis.
We help prevent future equipment failure through:
- Oil analysis
- Vibration measurements
- Visual inspections - looking at the abrasive wear patterns and gear tooth pitting
- Online condition monitoring
If equipment does fail, your biggest concern is naturally how to get it up and running again as soon as possible. However, discovering the root cause of a gearbox failure is just as important because it prevents further unplanned machine downtime. Our experienced specialists use the latest technology to troubleshoot and problem-solve all kinds of gearboxes.
Staying in top gear: overhaul and repairs
Even well-serviced gears require an occasional overhaul to prevent accumulative wear. Proactive planning means you can schedule the shutdown to match normal fluctuations in product demand.
Together with you, we can plan and carry out any further assessment and/or necessary action.
We take care of all the calculations and gear designs, and coordinate closely between engineering and services. Examples of overhaul and repair jobs include:
- Complete parts dismantling
- Parts condition evaluation
- Parts repair or replacement
- Rotating parts
- Designed components
- Commodity components
- Assembly and function test
For kiln and ball mills, we offer services on open girth gears, including:
- Delivery and replacement of shell sections below girth gears
- Delivery and installation of girth gear, pinion, fixation system and drives
- Change or reversal and alignment of girth gear, pinions and drives
Easy plug ‘n play solution for Symetro
Do you have a Symetro gear unit? It’s the ideal central drive solution for ball mills – it has high efficiency, long life and needs little maintenance.
Some of the first gear units, installed more than eighty years ago, are still in service, and spare parts are still available. Nothing lasts for ever, however. If your Symetro gear unit eventually does wear down, new rotating parts based on the latest gearing technology are the ideal plug and play solution.
The new rotating parts fit easily into the existing gear casing. You can also use the existing bearing housings and torsion shaft, and no civil engineering is required. Erection is easy and takes less than two weeks, and you can start at 100% load.