Success stories

Projects that keep plants running

When the manufacturer no longer has a solution or time is running out, we design and deliver the alternative.

4,000 HP electric motor during factory testing

4,000 HP motor with auxiliary starting motor on the test bench

4,000 HP electric motor replacing a gearbox and steam turbine

Sugar industry · Sugar mill in Mexico

From steam turbine to a 4,000 HP electric motor before the harvest season

Challenge

Shaft failure in the cane shredder's high-speed gearbox, with damage to other parts and the harvest season about to begin.

Solution

Replacement of the gearbox and turbine assembly with a 4,000 HP electric motor with an auxiliary starting motor, built by our partner OMEC.

Result

The harvest season started without delay and the mill reports significant operating and maintenance savings, with a projected service life of 20 years.

Food industry · Multinational bakery

Obsolete gearbox replaced without losing a shift

Challenge

A 20-year-old planetary gearbox on a dough mixer: oil leaks, failures, no spare parts and no response from the manufacturer.

Solution

A latest-generation planetary gearbox, more compact and with guaranteed spare parts, with custom-made accessories for a plug-and-play installation.

Result

Installed during the scheduled shutdown with guidance from our technician; by the next shift the line was running normally, with no unplanned stops.

New planetary gearbox installed on the dough mixer

New planetary gearbox before installation

1 shift to return to normal production

Render of the replacement right-angle gearbox with its welded steel base

120 days from engineering to delivery

±0.01:1 reduction ratio accuracy

Steel industry · Multinational steel company

Obsolete precision gearbox rebuilt from a 1976 drawing

Challenge

An obsolete high-precision gearbox with no original engineering: only a 1976 assembly drawing.

Solution

We defined the duty cycle, two manufacturers in northern Italy built it with standard products, and we added our own welded steel structure. Same mounting dimensions, reduced backlash adjustable with shims without opening the gearbox, and right-angle drives with factory-matched spiral bevel gears.

Result

Fine, repeatable adjustment in slab production, with fewer rejects from out-of-range variations. The first set of 3 units was delivered and the customer scheduled two more sets.

Steel industry · Steel mill in Mexico

Turret slewing gearbox: obsolete equipment replaced in 120 days

Challenge

Replacing the obsolete turret slewing gearbox while it was still in operation.

Solution

A planetary gearbox with an in-house welded steel base, validated with finite element analysis. Dual input: electric motor and backup pneumatic motor, with emergency brake. 37 kW at 900 rpm, 75:1 ratio, nominal torque of 29,446 N·m and maximum of 64,781 N·m, service factor 2.2.

Result

Within 120 days the new gearbox was at the customer's plant, ready to replace the obsolete unit.

Isometric drawing of the turret slewing gearbox with its base

Finished turret slewing gearbox in the workshop

Turret gearbox with its welded steel base and input shaft

64,781 N·m maximum output torque

120 days to the customer's plant

Drawing of the slewing and lifting system for a sludge tank

Slewing mechanism housing during manufacturing

Slewing mechanism housing with pinion seat, ready for shipment

90 days from approval to delivery

4 manufacturers from abroad coordinated on a single project

Chemical · Mining · Cement

Replacement of slewing and lifting mechanisms on a sludge tank

Challenge

Sludge tanks with mechanisms from the 1970s and 1980s, with no genuine spare parts, kept running by cannibalizing equipment. The customer had spent three years looking for a replacement manufacturer.

Solution

From photographs and an old layout, we designed a system with standard catalog gearboxes, lifting jacks and motors, with only the structure custom-made and validated by finite element analysis. Three engineers from our team and four manufacturers from abroad; accessories designed to make maintenance easier.

Result

Delivered in 90 days and installed by the customer. The tank runs without forced outages, and rake position and motor variables are monitored from the control room.

Concept & Detail Design + Procurement + Commissioning + Service

Does your equipment no longer have spare parts or manufacturer support? Tell us about your case.

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