ATEK Drive Solutions presents: Reliable and durable gear solutions that reduce your operating costs and increase efficiency.
What is meant by a “maintenance-free lubricated gear” for water treatment plants?
Ein maintenance-free lubricated gear for water treatment plants is designed and filled with special lubricants so that it operates without re-lubrication or oil changes . This is achieved through high-quality seals, corrosion-resistant materials, and long-lasting lubricants that are specifically designed for the demanding conditions in water treatment.
What specific advantages do these gears offer in water treatment?
The main advantages are significant cost savings from eliminated maintenance and reduced lubricant consumption, a higher plant availability due to minimized downtime (reduction of unplanned failures by up to 70%), a longer lifespan of the components (up to 50% increase) and an improved environmental compatibility due to the possible use of biodegradable lubricants.
Why is material selection, such as stainless steel, so important for gears in water systems?
Water treatment plants have a permanently damp and often chemically aggressive environment.Stainless steel or special protective coatings for gear housings are essential to prevent corrosion and thus ensure the longevity and reliability of the gear. This is a core aspect of maintenance-free concepts..
Are NSF H1 lubricants always necessary in gears for water treatment?
Although not always mandatory (if there is no direct contact with drinking water), NSF H1-registered lubricants provide additional security against contamination. Their use is recommended in sensitive areas of water treatment and underscores a high quality and safety awareness..
How can the longevity of a “maintenance-free” gear still be monitored?
Even “maintenance-free” gears benefit from periodic condition checks.These include visual inspections for leaks or corrosion, vibration analyses for early detection of bearing damage and temperature monitoring, to identify overload or developing defects. In oil-based systems, an oil analysis can provide insights.
What should I pay special attention to when selecting a maintenance-free lubricated gear?
Pay attention to corrosion resistance (material, coating), suitable IP protection classes,the chemical resistance of the lubricants and seals, the load capacity (e.g. FZG value) and the compatibility of the lubricant with the operating conditions. Consulting experts such as ATEK Drive Solutions is highly recommended. wie ATEK Drive Solutions ist hierbei sehr empfehlenswert.
What happens if incompatible greases are mixed in a gear?
Mixing incompatible greases can drastically reduce lubrication effectiveness or even eliminate it. This leads to increased wear, overheating, and premature failure of the gear, thus negating the advantage of maintenance-free operation.
Does ATEK Drive Solutions provide support in choosing suitable gears for water treatment plants?
Yes, ATEK Drive Solutions specializes as a system provider for the complete industrial drive train focusing on comprehensive technical advice and the development of customized special solutions.. We help you find the optimal maintenance-free lubricated gears for your specific needs in water treatment, based on decades of experience and the latest technology.
Maintenance-free gears in water treatment plants significantly reduce operating costs, for example, by savings of up to €10,000 annually for 50 drives, and often pay for themselves within two years..
By using high-quality long-term lubricants and corrosion-resistant materials the plant availability is maximized, reducing unplanned failures by up to 70% and extending the lifespan of the gears by up to 50%. Lebensdauer der Getriebe um bis zu 50% verlängert Careful selection of the gear type
Die sorgfältige Auswahl des Getriebetyps, the lubricant (e.g., NSF H1, biodegradable) and regular condition monitoring are crucial to fully exploit the advantages of maintenance-free systems and ensure a reliable continuous operation. Discover how maintenance-free gears from ATEK Drive Solutions are revolutionizing water treatment and helping you save costs and protect the environment.
Water treatment places high demands on the technology used. With the maintenance-free gears from ATEK Drive Solutions, you benefit from maximum reliability and minimal maintenance effort. Contact us at
Entdecken Sie, wie wartungsfreie Getriebe von ATEK Drive Solutions die Wasseraufbereitung revolutionieren und Ihnen helfen, Kosten zu sparen und die Umwelt zu schonen.
Die Wasseraufbereitung stellt hohe Anforderungen an die eingesetzte Technik. Mit den wartungsfreien Getrieben von ATEK Drive Solutions profitieren Sie von maximaler Zuverlässigkeit und minimalem Wartungsaufwand. Kontaktieren Sie uns unter this link, to learn more!
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Understand: The role of maintenance-free gears in water treatment.
Ein maintenance-free lubricated gear for water treatment plants increases efficiency and significantly reduces operating costs. Such advanced gear solutions optimize critical processes and contribute significantly to environmental protection.
Mastering the challenge of reliability
Unplanned gear maintenance often leads to significant operating hours loss. The switch to maintenance-free gear systems maximizes plant availability. Ein Gears with lifetime lubrication, a core feature of many maintenance-free models, extend maintenance intervals from quarters to years.
Specific requirements in focus
Water treatment plants have high demands: constant humidity, aggressive chemicals, and demanding continuous operation. Standard gears often cannot meet these conditions; specialized, maintenance-free gears with high-quality seals (e.g., IP67+) are essential here.
The path to optimized operating costs
Although initial costs for maintenance-free gears may be higher, they often pay for themselves within two years. Reduced workload, lower lubricant consumption, and minimized downtime significantly lower the total cost of ownership (TCO). A plant with 20 such gears can save thousands of euros annually just by eliminating regular maintenance tasks.Defining: Critical requirements for gears in water systems
Corrosion on gears in the humid environments of water treatment plants is a critical issue. Materials such as stainless steel or special protective coatings are essential for a durable gear.Stainless steel gears offer excellent corrosion resistance here. Also, corrosion-resistant gear units are necessary for such applications.
- Ensuring corrosion resistance through suitable materials such as stainless steel or special coatings for the gear housing..
- Ensuring waterproofness (e.g., through IP protection classes) to protect against moisture in the demanding environments of water treatment.
- Necessity of chemical resistance of the gear against aggressive media such as disinfectants (chlorine, ozone).
- Use of chemically inert lubricants and seals to prevent material degradation in the maintenance-free gears..
- Use of food-grade lubricants (NSF H1) in sensitive areas of water treatment to prevent contamination.
- Designing the gears for water treatment plants for high shock loads and reliable continuous operation (e.g., FZG >12).
Chemical resistance: A must in aggressive environments.
Disinfectants such as chlorine or ozone can attack gear components. Chemically inert lubricants and seals in a maintenance-free lubricated gear prevent degradation and premature failures. The lubricant used must remain stable against chloramine-T, for example.
Food-grade lubricants (NSF H1) for maximum safety.
In water treatment, preventing contamination is of utmost importance. NSF H1 lubricants (e.g., from KIC Krones) in the gears provide additional safety, which is particularly relevant for sensitive processes. Food-compliant gears must be considered here.
High load capacity and absolute reliability.
Failures of gears in water treatment plants can have serious consequences. Therefore, these gears must be designed for high shock loads and continuous operation (e.g., in aeration basins, FZG >12). A robust, maintenance-free gear is the key here.Benefit: Utilize the diverse advantages of maintenance-free lubrication.
The regular re-lubrication of gears is largely eliminated with maintenance-free solutions. Maintenance-free gears, especially in the demanding environment of water treatment, eliminates planned downtimes and significantly increases plant availability. Reports indicate that unplanned failures could be reduced by up to 70% after switching to such systems.
Realizing sustainable cost savings.
The elimination of manual lubrication reduces not only personnel costs but also material costs for lubricants. These direct savings from maintenance-free gear technology sustainably improve total operating costs (TCO). A typical water treatment plant with 50 drives can save over €10,000 annually by using maintenance-free gears.
Extending the lifespan of components.
According to SKF, about 36% of premature bearing failures are due to inadequate or incorrect lubrication. High-quality long-term lubricants (e.g., those with MicPol® technology from Interflon), as used in a maintenance-free lubricated gear, minimize wear and corrosion. This can extend the lifespan of the gears by up to 50%.
Actively improving environmental compatibility.
The environmental regulations for industrial plants, including water treatment plants, are becoming increasingly stringent. Biodegradable (according to OECD 301) and PFAS-free lubricants used in modern maintenance-free gear boxes for water treatment plants actively contribute to environmental protection and support compliance with legal regulations.Select: The optimal maintenance-free lubricated gear box for your water treatment plant find
Unsuitable housing materials can corrode quickly in the humid and chemically aggressive environment of water treatment plants. Stainless steel or specially coated aluminum alloys are crucial for the longevity of a maintenance-free gear box. Ein Hygienic Design gear box made of stainless steel is not only corrosion-resistant but also particularly easy to clean. For areas with intensive wet cleaning, it offers IP69k gear boxes additional, maximum protection.
- The choice of housing material (e.g., stainless steel, coated aluminum alloys) is critical for the corrosion resistance of the gear box in water treatment.
- Considering hygienic design principles and high IP protection classes (e.g., IP69k) for specific requirements and optimal ease of cleaning of the gear box.
- The lubricant in the maintenance-free lubricated gear box must be carefully tailored to the specific application, the sealing materials used, and the prevailing environmental conditions.
- Mixing incompatible greases (e.g., a marine grease with a lithium grease) can significantly reduce the lubrication effect and must be avoided to ensure maintenance-free operation.
- The NLGI consistency class of the grease (often class 2 or 3 for applications in water treatment) must be selected according to the speed, operating temperature, and type of seal of the gear box.
- Consulting experienced manufacturers (e.g., ATEK Drive Solutions) and lubricant experts is essential for the optimal selection of a maintenance-free gear box for water treatment plants is essential.
- Using expert tools (such as SKF’s LubeSelect) and specific manufacturer recommendations can support the selection process for the suitable gear box.
Lubricant type: More than just oil or grease for your gear box
Mixing incompatible greases (for example, a calcium sulfonate complex grease with a polyurea grease) can drastically reduce the lubrication effect. Precise matching of the lubricant to the application, seals, and environmental conditions of the gear box is critical. Synthetic oils often provide superior performance and durability for maintenance-free systems.
NLGI consistency class: Finding the right balance for the gear box grease
The consistency of the grease used is an important factor for the performance of the gear box. For gear boxes in water treatment plants, greases of NLGI classes 2 or 3 are often suitable. However, the exact selection depends on factors such as speed, ambient temperature, and the sealing system of the maintenance-free gear box.
Obtain manufacturer recommendations and expert advice
The advice of experts is of great value when selecting a specialized gear box. Consultation with gear box manufacturers (such as ATEK Drive Solutions) and lubricant experts ensures the selection of the optimal solution for your water treatment plant. Digital tools like SKF’s LubeSelect can further support the selection process for the right maintenance-free gear box.Monitor: Ensure the longevity of maintenance-free gear boxes
Even for gear boxes labeled as ‘maintenance-free’, periodic condition checks are advisable, especially in critical applications like water treatment. Regular oil analyses (e.g., determining water content according to Karl Fischer, particle counting according to ISO 4406) can reveal early issues in the gear box. Especially maintenance-free gear boxes for continuous operation in water treatment plants benefit from such preventive measures.
Visual inspection: Do not overlook the obvious on the gear box
External signs on the gear boxes should always be noted. Visual inspections for possible leaks, early corrosion, or unusual noise are simple yet effective indicators of the gear box’s condition. Early detection of such signs can prevent larger damages and failures.
Vibration analysis: Feel the pulse of the gear box
Beginning bearing damage or imbalances in the gear box can be early detected by vibration measurements. Vibration analysis is an established and effective tool of condition-based maintenance, even for maintenance-free gear boxes. Modern sensors can detect even the smallest changes in the vibration behavior of the gear boxes.
Temperature monitoring: Heat as a warning signal for the gear box
An unexplained or sudden heating of a gear box may indicate underlying problems. Temperature monitoring (manually or continuously via sensors) can indicate overload, insufficient lubrication or other defects in the gear box. Temperature deviations of more than 15°C from normal operating conditions require a closer investigation of the affected gear box.Optimize: Revolutionize water treatment with maintenance-free gear boxes
Maintenance-free gears, and particularly the specially designed maintenance-free lubricated gear boxes for water treatment plants, represent a crucial factor in improving efficiency, reducing operating costs, and enhancing environmental compatibility in modern water treatment. A careful selection, implementation, and monitoring of this advanced gear technology allows operators to harness their full potential and sustainably optimize their facilities. Comprehensive expertise and the choice of the right, long-lasting gear solutions are essential to ensure the further development and reliability of water treatment processes.
