To ensure every unit leaves our shop in peak condition, we follow a rigorous, documented restoration process:
Every gearbox undergoes a thorough external cleaning to remove years of production buildup, allowing our technicians to perform a clean disassembly and accurately inspect the housing for external cracks or leaks.
We carefully disassemble the unit, documenting the orientation and position of every gear, shaft, and shim. This step is critical for identifying the “root cause” of the failure rather than just treating the symptoms.
Using precision measuring tools, we inspect:
Gear Teeth: Checking for pitting, spalling, or micro-cracking.
Shafts: Checking for runout, wear at bearing seats, and seal surface integrity.
Bores: Checking for ovality or wear in the main housing bores.
This is where the Zala Advantage sets us apart. If a part is unavailable or has a 20-week lead time, we have the in house capabilities to reverse engineer the worn part and manufacture it:
Gear Manufacturing: We can machine new gear blanks and use our range of gear cutting vendors to cut precision gear teeth.
Housing Repair: We utilize our CNC boring mills to sleeve worn bearing seats, restoring perfect shaft alignment.
Shaft Recovery: Precision grinding and plating to restore worn seal diameters. Shaft machining has been one of the corner stones of Zala Machine since day one. We fix and machine new shafts for all types of applications.
The unit is reassembled with high-grade bearings and seals. For twin-screw gearboxes, we perform meticulous timing and backlash checks to ensure perfectly synchronized output.
We understand the varying complexities of drive systems across the polymer industry:
Single-Screw Gearboxes: Focus on thrust bearing integrity and axial load management.
Twin-Screw Gearboxes: Specialized alignment and timing for co-rotating or counter-rotating systems.
Capacity: We have the lifting capacity and large-scale machinery to handle everything from lab-scale units to massive production gearboxes.
“Most repair shops are just assembly houses—they order parts and wait. At Zala, we are a manufacturing facility. If your gear is stripped and the OEM is 6 months out, we machine a new one. We control the quality and the timeline.”
Our advanced CNC machining centers and an experienced team of engineers guarantee excellent results. Regardless of the complexity of the project or specification, we are ready to meet your requirements. Our machines are equipped with the latest technology.
