Gearbox and the energy saving myth

As a result of rising energy and raw material costs, seeking more efficient and energy-saving alternatives is inevitable. As demand increases for high performance gearboxes that are able to meet the specific cost-saving requirements of processors, development of new gearbox models tend to move towards ensuring stable operation, heightened performance at lower costs and greater durability.

Zambello gearboxes have been developed and launched with the intention to boost machine performance to meet the goals towards decreased costs. Understanding the role played by a gearbox in the extruder as an important component where main motor power is transferred from the motor to the extruder to amplify the torque, the design of the gearbox took into consideration the whole process. As the gearbox itself does not generate any power, so the more it completely passes on the power of the electric motor, then the more energy savings can be achieved. In domestic un-grinded gearbox generally, the transmission efficiency is about 75%~85%, which also means the motor spends $100 on the electricity, functioning drive gearboxes, and after gearbox passes the kinetic energy to the screw, it only cost $75~$85 to produce the extruded products, and the rest of the $15~$25 is the friction being converted to thermal energy, and was consumed by the gearbox, resulting in wastage. But Zambello Riduttori gearbox, which has been developed through R&D and the company’s design departments for the past 30 years with parts produced by Germany-made high tech grinding processing machines, has resulted in the grinding precision of each gear reaching the Germany standard DIN4 level. As a result, the energy transmission efficiency of the Zambello gearbox can be up to 92%, thus, reducing energy consumption which has been the target of every processor.

Eliminating higher consumables costs

In the market, there are also other gearboxes that emphasize on energy saving, with some of the products aiming to extend the life of the consumables, such as stretching the frequency on the replacement of lubricating oil, to achieve the so-called energy-saving effect. But the cost of the consumables when the gearbox has run for one year indicates that the proportion is actually very low, thus providing an unattractive option for processors.

Zambello gearboxes have been providing significant improvement in the operation that a large number of manufacturers have been using these products for significant results. For instance, in a production plant where required capacity is 5000 tonnes per hour, using extruder assembled from common gearbox might require the purchase of 8 to 9 production lines equipment in order to meet the demand, whilst also preparing a relatively large enNike Air Max 95