Extruder Gearbox Repairs - Highfield Gears

Extruder Gearbox

In the rubber, polyurethane and plastics industry, gear units such as these are very, very prominent. While they may be a specialist product when compared to worm gearboxes, bevel helical gearboxes and other industrial gearboxes they are no less important for the businesses that use them.

Here at Highfield Gears, we know the importance of these systems which is why we have worked hard and invested in cutting-edge equipment, since our founding in 1927, to offer a gearbox repair service for extruder gearboxes which can ensure a cost-effective manufacturing and maintenance process.

Our extruder repairs team at our gear machine shop based in Huddersfield have spent, collectively, decades helping businesses and organisations across the UK and Europe such as Polypipe and Ineos with their series of units. They channel this engineering expertise into helping you with these types of gearboxes to ensure they achieve maximum reliability and efficiency so you can focus on your business’s goals and not annoying equipment issues. We can help repair extruder gearboxes that are our own or from the original manufacturer such as Krauss Maffei, Falk, Battenfeld, Weber, Thyssen, Eisenbeiss. As well as this, we also offer a 24/7 emergency service that can have your extruder gearbox fixed through the night to limit downtime and manufacturing costs.

So, if you’re based in the UK in places such as Birmingham, Manchester, Glasgow or you’re further afield in Europe and need gearbox maintenance, reconditioning or repairs be sure to get in touch with Highfield Gears today by phone on 01484 531 010 or email us at sales@hgi-uk.co.uk.

What Is An Extruder Gearbox?

Units such as these often include some sort of thrust bearing assembly on the output shaft which helps to counter the extruder screw. The gear components in these systems must be smooth when engaging with other drives so the subsequent vibrations don’t affect the extrusion process. Further, an extruder gearboxes’ input shafts are designed to allow vee belt loads and the occasional overload from so-called ‘cold starts’.

Extruder gearbox drives can transmit the high torque that is required for pressurising and plasticising moulding materials. This series of gears can also absorb the high axial thrust load thanks to the built-in spherical roller thrust bearing. Typically in this series of gearboxes, the axial bearing housing component is standardised to accommodate the suitable thrust bearings and corresponding output shafts. Another characteristic requirement of this series is the parallel shaft double reduction models, further, to incorporate the thrust screw there are often different bores that are mounted on the output shafts which have a range of thrust bearings. Plastics and rubber companies enjoy these industrial drive solutions because they are easy to install, offer maximum operating reliability, are quiet and run smoothly all while offering good levels of efficiency.

Engineering of this type is complex and the correct gear cutting and reconditioning needed to ensure extruder gearboxes can work effectively is vital. Even if one component element of these gearbox units falters, the whole thing will break down. At Highfield Gears, we understand this is why our service team works incredibly hard to offer a bespoke, comprehensive gearbox repairs service.

Extruder Gearbox Applications

Extruder gear units are used in machinery that is primarily found in two key industries – the rubber industry and the plastics industry, as we’ll explain. At Highfield Gears, we have a huge deal of experience in the extrusion process and can apply our decades-old solutions to the latest extruder gear unit. The range of extruder units we have worked on makes us ideally suited to help you, no matter whether you’re in the rubber or plastics industry.

There are plenty of features and advantages in extruder gearboxes. Once our team has examined your machinery you’ll soon be able to enjoy a quality extruder gearbox once again.

Rubber Industry

Rubber Industry

It may not immediately spring to mind, but the rubber industry is one of the biggest global industries in the world. The rubber industry itself is split into sectors – the tyre sector, and the non-tyre sector. The former incorporates all types of automobile tyres. The latter, the non-tyre sector, looks at medium and small scale units that produce sophisticated industrial products.

An extruder gear unit is a preferred product used by businesses and organisations in the rubber industry. This is because of the extremely high levels of torque that the extruder unit produces. The torque is needed to force through the rubber and create the tyre, and non-tyre products. They pressurise the rubber material and can absorb the high axial load at the same time.

The pressures that are involved in creating tyres and other similar products mean that the extruder gear drive must be kept in optimum condition at all times. If the torque levels cannot be maintained and sustained, then the rubber product will not be at the high standards set.

Plastics Industry

Plastics Industry

These types of gearboxes are similarly used in the plastics industry. Unlike the rubber industry, which is split into two distinct categories, the plastics industry is broader and incorporates a much larger range of subgroups. You only have to look at how much plastic is used. From single-use items that protect food, to larger pieces of plastic that are used in televisions, computers, and other electronic items.

In general, the extruder drive works as follows. Plastic pellets are fed into the extruder and are gradually melted by mechanical energy. This energy is generated by a turning screw (which gets its power from the extruder gearbox) and the large heaters that are arranged along the barrel. These pellets, which form a molten polymer, are forced through a die, into shape, by the extruder drive.

Which Gear Is Used In These Extruder Gear Units For High-Speed Reduction?

In these types of gear units, the need to slowly force a raw material through a small area means that a low speed is often necessary. Too fast a speed and you run the risk of damaging your gearbox’s internal components. Very often, these slow rotational speeds can be calculated in rounds, or fractions per minute such is the precision and care that is needed to ensure the materials are manipulated properly.

This requires high ratios and output torque values. To be able to achieve such a high ratio and torque level. There are a variety of gears that can be used: Double worm reduction gear; Coaxial; Coaxial and parallel axle; Ortogonal coaxial; Multi-stage planetary gearbox; Worm reduction gear.

How We Can Help You With This Type Of Industrial Gearbox Repairs

Right from the get-go, you'll soon see that, here at Highfield Gears, we offer a truly thorough, comprehensive and knowledge-led process that can transform the capacities and capabilities of your extruder gearbox.

Our services range from gear manufacturing including bevel gear, helical gears and worm gears to the complete refurbishment of extruder gearboxes if needs be. We have invested heavily in industry-leading equipment such as gear milling, cutting and CNC machines which allows us to be nimble and offer services at a speed few can match.

We understand the need to optimise our solutions to deliver you maximum production capacity, we do this by ensuring your transmissions have high capacity rolling elements and thrust bearings that are fitted into rigid housings, all to disperse the thrust load from the extruder without risking internal misalignment – which can have you back at square one pretty quickly.

The minute your extruder gearbox arrives at our gear centre in Huddersfield we’ll undergo a thorough analysis, take photos and write up a report before going ahead and delivering bespoke solutions, whether that’s manufacturing individual gears or completely stripping, up to 18-tonnes, the gearbox itself. We have a wide range of in-house capabilities to manufacture and produce any and all parts needed which, in turn, speeds up the overall repair or reconditioning service because our team isn’t waiting on a product, gear or casing to arrive from the UK or overseas. This allows us to get the job done quicker, track quality throughout the process and provide photos and reports at every stage so you feel comfortable and informed about our services and processes.

Our 24/7 Emergency Repair Service

Extruder machinery offers slow rotational speeds and high levels of torque. They are used in crucial manufacturing processes and are vital components for businesses that need to fulfil orders by making products using the extrusion process. Therefore, when something goes wrong, the problem needs to be fixed immediately. In such a global world of trade, these problems can occur at any time of day or night.

Thankfully, at Highfield Gears, we offer a 24/7 emergency repair service. This means that a member of our team is on call to come and inspect and repair your extruder gearbox whether it’s in the middle of the afternoon, or at 2 am on a Sunday. This kind of service should give you peace of mind knowing you can continue to manufacture and not have to worry about what you’ll do should something go wrong at an inconvenient time.

Simply get in touch with our team and we'll be there straight away to ensure business operations are not affected.

Features And Benefits Of Extruder Gearboxes

For several businesses, these types of gearboxes are extremely popular thanks to their speed, efficiency, torque and ease of installation. What follows are just a few of the benefits and features that are prominent in these types of transmissions.

High Torque Levels

A great deal of torque is produced by these transmissions which help drive extruder screws.

Bespoke Design

The design of the output stage is bespoke and designed to interact with the extruder for a perfect gearbox fit.

Optional Extras

Users have an option to include features which can directly drive the extruder screw such as hollow shafts.

Internal Lubrication

There tends to be internal lubrication systems built in to aid smooth operations and reduce any excess heat.

High Loads

They can support very high thrust loads.

Hollow Shaft

A hollow shaft can be fitted to suit the extruder configuration.

What Is An Extruder?

The machinery behind an extruder helps to achieve a range of tasks, and, as we have seen, are used in two of the biggest industries in the world. To understand what an extruder is, let's first look at the extrusion process, the primary function of these types of gears.

This process typically starts with raw materials such as pellets, dry powder, rubber, plastics, or even food, being pushed through a die. This die is a mould that shapes the material because it is forced through a smaller opening through the other side. Extrusion is one of the most common ways manufacturers create sheets and strips of metal, plastic, and rubber. All of which are used in thousands of different ways. The extruder itself aids this process and is powered by a gearbox of the same name. This piece of equipment is used to complete the process and uses a system of barrels and cylinders to propel the material through it to create the desired shape.

The kind of pressures and stresses involved are the reason why slow ratios, and high levels of torque, are needed.

Contact Highfield Gears Today

If you’re a business that uses extruder gearboxes for whatever reason and you think you might need it repaired, reconditioned or upgraded then be sure to get in touch with us here at Highfield Gears today. Whether you’re an expert or someone who has no idea about these types of gearboxes we can help you figure out what is wrong, repair it and offer recommendations about how you can prevent problems from happening in the first place.

So, if you’re based in the UK in areas such as London, Bristol, Newcastle or anywhere else in this country or Europe give us a call on 01484 531 010 or email us at sales@hgi-uk.co.uk – we look forward to helping you.