Maximum Plant Availability Starts with the Extruder Gearbox

In extrusion, compounding, and recycling, the reliability of every single system component determines a plant’s efficiency and profitability. One very critical component is the extruder gearbox. Transmitting high torque through the twin screws to the processed material, it has a direct influence on both extruder performance and final product quality.

Our comprehensive gearbox service package is the key to avoiding unplanned downtime and significantly extending the service life of extrusion systems. This service ranges from continuous condition monitoring and predictive maintenance to fast gearbox replacement solutions. Operators benefit from higher system availability and, consequently, maximum Overall Equipment Effectiveness (OEE).

Gearbox Monitoring: Detect Problems Early Instead of Reacting to Failures

Many gearbox failures show clear signs long before an actual breakdown occurs. With our advanced VibeTrack condition monitoring system, these indicators can be identified at an early stage. Multiple sensors installed on the ZSK twin screw extruder continuously monitor key gearbox parameters such as vibration behavior and oil condition. This provides a transparent overview of the gearbox’s current operating conditions. Coperion experts can provide prompt remote support and give valuable recommendations whenever required.

As an alternative, our experienced service specialists can perform regular vibration analyses. Using mobile measurement equipment, we detect and evaluate mechanical irregularities in extruder gearboxes. Necessary maintenance measures can be planned in advance, significantly reducing the risk of costly production downtime.

Fast Support Through an Expanded Exchange Program

If a gearbox overhaul becomes unavoidable, one factor matters most: time. That is why Coperion has significantly expanded the availability of exchange gearboxes in recent months. For numerous extruder sizes and configurations, we keep refurbished and quality-tested gearboxes in stock, ready for fast delivery.
The concept is simple: The existing gearbox is replaced with a matching, already refurbished exchange gearbox. Production interruption is limited to the actual replacement process. Within a very short time, the extruder can resume full-capacity production at maximum performance.

This ensures reliable plant operation for years to come without unexpected interruptions. For newly installed exchange gearboxes, we even offer extended warranties of up to 24 months.

Refurbished to the Highest Quality Standards

Our experts carefully refurbish old extruder gearboxes at one of our gearbox service facilities in Stuttgart/ Germany, Wytheville/VA//USA, Niel/Belgium, or Nanjing/China. Following complete disassembly, all components are cleaned, inspected, and documented. Wear parts are replaced, critical components are overhauled, and all relevant functional parameters are thoroughly checked.

Upon completion, every gearbox receives a detailed condition and repair report. Once it successfully passes all inspections, the gearbox is approved to be added to the exchange program inventory.

Coperion Gearbox Service Program – Your Benefits at a Glance

• Increased plant availability through predictive condition monitoring
• Reduced risk of unplanned production downtime
• Short downtime thanks to readily available exchange gearboxes
• Professional refurbishment by experienced gearbox specialists
• Detailed inspection and condition reports for maximum transparency
• Extended warranties of up to 24 months on overhauled exchange gearboxes
• Sustainable extension of extrusion system service life