CASE STUDY - KILBUN
The Gearbox Problems We Faced
Before finding the right solution, we had to undergo an inspection to figure out what was wrong, and what steps we needed to take. Our findings showed us that Heavy pitting and line marks seen on teeth of
Input pinion and output wheel, Light corrosion seen face and whole body.
Within the gearcase itself, we found that the bores were within the accepted tolerance but the lube system in the gearcase needed re-piping after failure.
In general, there was damage to the bearings and seals, all of which would need replacing.
The Gearbox Services We Used to Fix the Issue.
It was clear that the gearbox had a lot of problems, so after informing the client about the issues and the client's permission by supplying photographs and a detailed inspection report, we started working to address the issues.
We began by re-piping the lube system. we opened the gearbox, removed input pinion, and output wheel for machining process on it. first, we removed all corrosion by using suitable agent. We did first grinding
process for removing dent and pitting. Then, did buffing process for smoothness. After that did NDE on components and gearbox casing.
We also fitted brand new bearings, seals, and fasteners to ensure a smooth power transmission at time of gearbox assembled. We did no load test on our works shop after that. In which we checked temperature,
vibration, and noise level a different interval time.
we had finish repairing work of gear unit and installed it to customer site. We tested (in load condition) the refurbished gearbox to our incredibly high standard to ensure everything was running smoothly,
and that the gearbox could be used for its intended application.
Reliable Industrial Gearbox Solutions for Heavy-Duty Operations
Formura offers comprehensive industrial gearbox services designed to ensure smooth, efficient, and uninterrupted operation of critical rotating equipment across industries. Our expertise covers inspection, repair, refurbishment, maintenance, and performance optimization of all types of industrial gearboxes used in heavy engineering applications.
Industrial gearboxes are vital components in power transmission systems, responsible for controlling speed, torque, and direction in machinery. Any failure or inefficiency in a gearbox can lead to costly downtime and production losses. That is why we provide end-to-end gearbox engineering solutions focused on reliability, durability, and performance enhancement.
What is an Industrial Gearbox?
An industrial gearbox is a mechanical device that transmits power from a prime mover (such as a motor or engine) to an output system while adjusting torque and speed according to operational requirements. These gearboxes are used in heavy-duty applications where high torque and controlled motion are required.
Common types of industrial gearboxes include:
Helical gearboxes
Bevel gearboxes
Worm gearboxes
Planetary gearboxes
Parallel shaft gearboxes
Custom gear systems
Our Industrial Gearbox Services
Formura provides a complete range of services to support industrial gearbox lifecycle management, from installation to refurbishment and performance improvement.
1. Inspection & Condition Monitoring
We conduct detailed inspection and diagnostic analysis of industrial gearboxes to identify wear, misalignment, lubrication issues, and internal damage. Our condition monitoring approach helps prevent unexpected breakdowns and improves operational reliability.
2. Repair & Overhaul Services
Our repair and overhaul services restore gearboxes to optimal working condition. We handle complete disassembly, cleaning, inspection, part replacement, reassembly, and functional testing. We specialize in repairing gears, shafts, bearings, and seals.
3. Refurbishment & Re-engineering
We offer advanced refurbishment solutions to extend gearbox life and improve performance. Our re-engineering process enhances efficiency, upgrades weak components, and ensures compliance with modern industrial standards.
4. Spare Parts & Fabrication
We provide high-quality spare parts and replacement components for all types of industrial gearboxes. Where required, we also manufacture custom components based on drawings or reverse engineering.
5. On-Site & Emergency Support
To minimize downtime, we provide on-site gearbox maintenance and emergency repair services. Our technical team is equipped to handle urgent breakdowns and restore operations quickly and efficiently.
Applications of Industrial Gearboxes
Industrial gearboxes ensure smooth torque transfer and operational efficiency in demanding environments across a wide range of heavy-duty applications:
Cement and steel plants
Oil & gas industry
Power generation plants
Sugar and paper mills
Mining and mineral processing
Material handling systems
Marine and offshore equipment
Heavy manufacturing industries
Common Gearbox Problems We Solve
Industrial gearboxes operate under high load and continuous stress, making them prone to wear. We specialize in diagnosing and resolving:
Gear tooth wear, pitting, and surface damage
Bearing failure and shaft misalignment
Lubrication system malfunction and leaks
Excessive vibration and high noise levels
Shaft damage and keyway wear
Overheating and efficiency loss
Why Choose Formura?
Formura is trusted for delivering high-quality engineering solutions backed by technical expertise and industry experience. We focus on improving equipment performance while reducing downtime and maintenance costs.
Expertise in all major gearbox types and brands
Advanced diagnostic and repair capabilities
Strong focus on safety and operational reliability
Custom engineering and reverse engineering support
On-site and off-site service flexibility
Cost-effective lifecycle solutions
We ensure every gearbox is restored to maximum operational efficiency through precision engineering and quality control.
Our Service Process
1
Initial inspection and failure analysis
2
Technical evaluation and reporting
3
Repair and refurbishment planning
4
Component repair or replacement
5
Assembly and alignment
6
Load testing and quality validation
7
Final performance optimization
Quality Assurance & Performance Testing
Every industrial gearbox service at Formura undergoes strict quality checks to ensure optimal performance. Our goal is to ensure that every gearbox meets operational standards and performs reliably under real-world industrial conditions.
We perform:
- Vibration analysis
- Load testing
- Thermal performance checks
- Alignment verification
- Lubrication system validation
Industries We Serve
Our industrial gearbox solutions are widely used across multiple sectors:
Heavy Engineering
Energy & Power Sector
Oil & Gas Industry
Cement & Construction
Marine & Offshore
Manufacturing & Automation
For reliable and efficient industrial gearbox services, connect with Formura today. Our engineering team is ready to provide customized solutions to improve equipment performance, reduce downtime, and enhance operational efficiency.
CASE STUDY - PSP
The Industrial Gearbox Issues We Face.
Once our specialists got to inspect the details of the gearbox. They make inspection report to quickly discovered series of issues and make workflow chart to quick resolution of it.
They visually checked Input pinion shaft and noticed that there is very heavy corrosion, Scratch mark and pitting observed on outer diameter and Input bearing pitted due to more RPM.
Checked Intermediate gear wheel & pinion in which all inter mediate bearing are good condition, Heavy corrosion, Scratch mark and pitting observed on outer diameter. Keyway & oil seal dia. damage. Also,
observed Slight burr at output pair tooth. (Gearwheel & Pinion).
The Gearbox Repair Solutions We Implemented.
Inspections and diagnostics complete, we got to work applying our bespoke solutions to the problem to ensure that Lubrizol would have a gearbox that was back working to the standards they expect.
We started by manufacturing and fitting a new high-speed input pinion shaft with keyway. Also changed the oil seal.
Burrs were removed from the intermediate gear wheel and pinion by a grinding and polishing process. Built up a new output shaft through reverse engineering.
We did no load test on our works shop, in Which we checked temperature, vibration, and noise level to ensure everything was running smoothly, and that the gearbox could be used for its intended application.
CASE STUDY - UPL
The Gearbox Problems We Faced
Upon inspection by our skilled engineers, we found heavy damage on the keyway of the inner diameter of the hollow shaft. It was also found that the outer diameter of the shaft was heavily rusted and bore
heavy scratches.
Heavy dent and corrosion observed on outer dia. Of output shaft’s, Keyway also damage, Slight pitting & wear marks observed on 1st intermediate pair, 2nd intermediate & output wheel.
The gearbox repair team then moved on to cleaning the gearbox. the only solution that would work would be a complete replacement.
The Gearbox Services We Used to Fix The Issue.
Our experts have observed the problem and made a report on what needs to be done in this gearbox and started the work under the guidance of the production head.
First replaced the output oil seal, made a new keyway through CNC machine. Then, a machining process was performed on the shaft to remove traces of rust and heavy scratches.
Using all suitable agent to remove corrosion. We manufactured a new output solid shaft and made a keyway on it. We also refitted the existing input coupling with new keys to improve power transmission and
overall performance and supplied new bearings, seals, and fasteners.
Once we had finished repairing the gear unit, we then tested the rebuilt gearbox to our incredibly high standard, to ensure everything was running smoothly, and that the gearbox could be used for its intended application.
CASE STUDY - UPL REACTOR
Service and Overhauling of Reactor Gearbox.
We’re proud to be able to offer a wide range of gear services and overhauling solutions., we have the equipment and technology in house to make the parts that help us fix and repair new or reconditioned gearboxes.
our service engineer visited at customer site for visual inspection of gearbox. They observed and noted that there is Dent & scratch marks, corrosion too at input pinion. Also found Pitting scratch marks
and oil seal damage. In intermediate Spiral bevel Pinion & wheel found Bearing choke up at Spiral Pinion Tooth side & spline side, built up edges & brush observed on gear teeth, Dent & scratch marks
observed at input pinion and Corrosion Observed at Pinion.
we suggested to the customer that due to lack of skill labour and necessary tools, the work at the site was not possible, so the work of this gearbox will have to be done at our workshop.
After the gearbox reaches our workshop, our skill fitter team disassembles it completely and the service engineer prepares an inspection report so that we can know what the problem with the gearbox is. After
that our production department made a workflow chart according to the priority of the work.
As per the workflow chart, our technical team start the repairing of gearbox. They first completely disassembled the gear box and took out Input Pinion, Intermediate Spiral bevel Pinion & wheel, Planet Carrier
with Sun Gear Wheel, Sun Pinion, and Output shaft. Grinding and polishing work was done as per requirement. Sun pinion which was completely worn out was reverse engineered and rebuilt. Deburring on spline,
gear teeth were also smoothed using suitable tools. The condition of Bering was correct so there was no need to change it.
After fully servicing the gear box, our QC department will do no load test of the gear box, and check the noise, vibration, temperature at 1-1-hour intervals, and check if there is any oil leakage Yes or
No. Installed it at the customer's site only after satisfactory condition and tested it under full load as well. Customer is very happy because of our service and fast delivery.
