gearbox repair

Coffee Creamer Bottle Motor/Gearbox Repair

In a coffee creamer plant, the blow molding machine was the backbone of the operation, producing 16oz and 32oz bottles. The process started with plastic pellets being fed into the machine through a hopper or screw. These pellets were heated and melted due to the combined effects of external heat bands and the friction generated by a rotating screw. The melted plastic was then shaped into a parison, a hollow tube with an opening at one end, which was clamped securely inside a mold designed to form the bottle. Compressed air was then forced into the parison, causing it to expand [...]

Coffee Creamer Bottle Motor/Gearbox Repair2025-07-23T13:36:11-04:00

Cement Plant Finish Mill Project

The electric motor plays a crucial role in the operation of a cement ball mill. It provides the power necessary to rotate the mill’s cylinder, which contains grinding media such as steel balls. This rotation of the cylinder causes the grinding media to cascade and grind the raw materials or clinker inside the mill into fine powder. The motor’s power and efficiency directly impact the performance and productivity of the cement ball mill. A properly sized motor with sufficient power ensures that the mill can handle the required load and maintain the desired rotation speed. Additionally, the motor’s reliability and durability [...]

Cement Plant Finish Mill Project2025-01-15T13:28:15-05:00

Pinion Gear for Crusher

In the latest triumph of efficient problem-solving, our team at Horner Machining Services swiftly came to the rescue when an aggregate plant faced a crusher system outage due to a damaged pinion gear for their primary crusher. Understanding the urgency, we executed a super quick turnaround, minimizing downtime and financial losses for the plant. The significance of pinion gears and racks in the mechanical world cannot be overstated; their toothed design along flat surfaces con- verts rotational motion into linear motion, forming an integral part of traditional drivetrains. Fun fact: the first commercially successful steam locomotive featured a pinion gearbox! At [...]

Pinion Gear for Crusher2024-11-15T12:58:05-05:00

Horner Springfield: Sulzer Pump Company Repair Center

          There is an old saying that when you mix water and electricity, water will always win. Judging from the amount of submersible work that the Horner Springfield division has been receiving, I would say that the old saying is very true. We have seen a substantial increase in the number of underwater submersible pumps and agitators that have a motor, gearbox and fan. Part of the reason for the increase in this line of repair work is the long lead time for replacement units. Underwater submersible equipment that our division has repaired ranges in size from [...]

Horner Springfield: Sulzer Pump Company Repair Center2024-02-28T09:37:03-05:00

German Engineering Gearbox

Anyone who has worked in the field of electromechanical repair has likely come across one or more pieces of German engineered equipment. It doesn’t take long to figure out the Germans have a unique way of engineering their products and for the most part, are not repair friendly. Recently our shop repaired a Knodler CMG gearbox that was designed and built in Germany. The design of the CMG gearbox is to solve a problem of needing a large amount of torque in a small package, and this gear- box does that well. CMG is an acronym for “compact motor gear” and [...]

German Engineering Gearbox2023-03-15T10:24:40-04:00

Aluminum Plant Outage

A major aluminum manufacturer contracts Horner EMDS (Electro Mechanical Diagnostic Services) to perform monthly vibration data collection and analysis. EMDS identified a mill gearbox input shaft bearing issue. In 2022, the monthly vibration analysis indicated the bearing issue increasing. The vibration analysis was discussed with the customer and the vibration data collection increased to twice weekly. At the same time, customer was planning a major outage to on-site repair the gearbox. The March outage was scheduled. Horner provided 24 hour per day, 5-day work schedule. On a Monday the outage started. Mark Rosebrock was lead tech on day shift and Matt [...]

Aluminum Plant Outage2023-03-14T11:27:59-04:00

The High Costs of Production Losses

In November, Bill Roper received a call from a concerned customer with a failed gearbox. This was a large obsolete gearbox that is coupled to a rubber extruder that mixes a special compound, supplied to other facilities. Bill asked if the Springfield division could commit the manpower to this overtime job and we accepted the challenge. The customer stated that his company was losing $550 every 15 minutes that this extruder was down. So that is $2,200 per hour, $52,800 per day and $369,000 per week! Needless to say, this was a full overtime job, worked around the clock. The customer [...]

The High Costs of Production Losses2023-03-06T11:22:25-05:00

Rolling Mill Gearbox Repair

A customer recently sent in a gearbox that is part of their rolling mill. The rolling mill uses a metal alloy to make engine bearings for large Diesel engines. This line on the mill brings in thicker material and rolls it out thinner to the desired thickness. Much like a rolling pin does with dough. The problem with the gearbox was when it was put under load it would vibrate like crazy. When the gearbox ran unloaded it ran smooth. It was found that the shaft was bent, and the gears were in bad shape. We worked with a quality manufacturer [...]

Rolling Mill Gearbox Repair2021-02-18T18:45:06-05:00

Plastics Company Gearbox and Roll Application Upgrade

An Indiana Plastics Company used a single chain, with a multiple sprocket setup to control their process equipment. They wanted to upgrade their systems to modern equipment and have the ability to vary the line speed. The customer decided to use (1) motor/gearbox and VFD per roll to allow for independent control. Horner was able to provide Sumitomo motor/ gearboxes and Horner Machining Service designed and machined a new drive shaft and coupling for each roll. These 8’ long 20” diameter rolls are water cooled so Machining Services had to figure out how to allow water to flow through the drive [...]

Plastics Company Gearbox and Roll Application Upgrade2021-01-10T16:50:22-05:00

Aluminum Plant Outage

In June of 2017 an Aluminum plant contacted us to begin the early planning stages of their outage which was scheduled for January 2018. The customer was about to undertake the most involved outage on their primary mill and wanted Horner’s exclusive involvement. The outage was a success despite the very large scale and daunting tasks assigned. All work was coordinated by Ralph Coonce of field service. If you’ve ever seen Ralph in action during an outage I don’t have to explain that he doesn’t just show up. He’s elbow deep in the actual work turning wrenches or any another task [...]

Aluminum Plant Outage2019-09-09T17:28:00-04:00

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