Flender gear units for water screw pumps provide a complete solution for lifting water in treatment plants and drainage systems, handling dirty liquids and minor solids with high reliability Each unit is delivered mounted on a basic frame, with a splash‑lubricated bevel‑helical gearbox, and can include an optional backstop to prevent reverse rotation caused by backflow . These units feature low noise emission, low vibration levels, and high overall efficiency, making them ideal for municipal wastewater plants, dewatering stations, and irrigation systems, wherever water must be raised to a higher level.
Flender’s standard industrial gear units encompass helical and bevel‑helical designs that cover nominal torques from 3,100 Nm up to 1,400,000 Nm across 28 frame sizes. They offer transmission ratios from i = 1.25 up to 450 and support both horizontal and vertical installation orientations for maximum layout flexibility. The compact modular design allows base‑ or shaft‑mounting, simple integration of auxiliary components (motors, backstops, seals), and rapid worldwide availability.
Fast Track® gear units are a special selection from Flender’s standard range available in small quantities (up to three units per type) and typically delivered ex‑works within 21 working days from order acknowledgement. They include predefined configurations with common ratios, seals, and add‑on parts, simplifying the ordering process; required order details include type, size, design, transmission ratio, seals, and add‑on components.
Flender’s conveyor belt drives are offered in three series—H‑series, E‑series, and A‑series—tailored for material handling in mining, cement, and bulk industries
H‑Conveyor Gear Units are compact, high‑power‑density helical units available in 25 sizes, benefiting from a modular accessory system (oil supply, backstops, fans) and worldwide short lead times.
E‑Conveyor Gear Units provide enhanced cooling for extreme ambient conditions, using axial fans and optimised air‑guide hoods to maintain stable operating temperatures in hot, dusty environments; available in 10 sizes for multi‑drive high‑power applications.
A‑Conveyor Drive Systems are self‑aligning, pre‑assembled units requiring no on‑site alignment, ideal for confined spaces and rapid installation, with patented self‑alignment and “CleverCooling” systems for optimized heat dissipation.
Flender offers a range of multi‑stage planetary gear units optimised for high torque density and modular flexibility.
PLANUREX 2 Standard Series covers nominal torques from 117,000 Nm to 2,600,000 Nm across 22 sizes with transmission ratios from i = 25 to 4,000, suitable for horizontal or vertical mounting.
PLANUREX 3 Standard Series extends the portfolio to torques from 480,000 Nm up to 5,450,000 Nm in 17 sizes, offering ratios between 1:45 and 1:300, combining premium power density with short global delivery times and excellent price‑performance ratio.
Flender wet cooling tower gear units are two‑stage bevel‑helical drives engineered to handle enormous ventilation forces by incorporating an additional axial bearing in the output shaft assembly. The motor is mounted outside the tower and linked via long composite couplings to the inside‑tower gear unit, ensuring easy maintenance and high reliability in continuous operation. These units are designed for heavy-duty forced ventilation applications in power plants and industrial process cooling systems.
Bucket elevator gear units are specialised bevel‑helical drives for high‑capacity vertical conveyors, handling bulk materials over heights often exceeding 200 m. They are configured as three‑stage gearboxes on base or swing bases, paired with fluid couplings for soft starting and auxiliary drives with backstops as standard, delivering input powers from 10 kw up to 1,850 kw, transmission ratios of 25–71, and torques up to 240 kNm. Flender’s application‑specific modular system ensures rapid availability and optimised operational reliability.
Aerator gear units are vertical‑mount bevel‑helical drives designed for biological aeration in wastewater treatment, featuring output shafts with oil‑retaining tubes and non‑contacting, non‑wearing labyrinth seals to prevent gear oil contamination. Extra‑heavy‑duty output shafts and bearings absorb high axial and lateral loads from impeller operation, ensuring continuous oxygenation with minimal maintenance.
For sugar mills, Flender’s PLANUREX 3 L individual‑drive planetary gear units deliver reference torques up to 2,250 kNm and ratios up to 1:300 in a lightweight, compact design, reducing structural loads on rollers and mill foundations. The optional direct‑mount oil supply system on the gear unit consolidates lubrication components into a single package, further enhancing footprint efficiency and lowering secondary forces. Optimised gear meshing and harmoniously spaced torque steps maximise energy efficiency and simplify gear selection for precise near‑point operation.
Flender crusher gear units include planetary designs with nominal torques from 22,000 Nm up to 2,600,000 Nm and transmission ratios between 25 and 125, providing compact, space‑saving installations with global service support. The H3SH helical crusher gearbox variant features a wall‑mounted, modular system with FLUDEX fluid couplings to mitigate torque spikes from blockage events, eliminating the need for heavy flywheels and frame structures.
Flender’s NAVILUS® marine gear units cover a full spectrum of ship propulsion drives:
Multiple‑Input/Single‑Output Marine Gearboxes direct outputs from several engines or motors to a single propeller, supporting up to 50,000 kw per engine, with clutch options for single‑ or twin‑engine operation, low noise, low vibration, and high efficiency.
2‑Speed Gearboxes provide dual speed modes for redundant, hybrid, or emergency drive systems, spanning 1,800–10,500 kw centre distances 710–1,250 mm, used in tankers, research vessels, fishing, and rescue ships.
Single‑Input/Single‑Output Gearboxes serve river, coastal, and ocean‑going vessels with power ranges from 1,000 kw to 30,000 kw and ratios of 1.5 to 12.1, optionally integrating PTO/PTI functions for onboard power generation.
Central mill drives for tube mills employ load‑sharing DUORED 2 and PLANUREX planetary gear units to drive mills directly from the end face without a girth gear, handling harsh, dusty conditions in cement and mineral processing. PLANUREX 3 central drives (HCCP) feature compact, low‑maintenance designs, high manufacturing quality, and optimised gear geometry, offering cost savings in mill structure and long service life under heavy loads.
Rotary kiln gear units are two‑stage bevel‑helical drives with torsionally rigid, foot‑mounted housings, case‑hardened gear teeth, and robust bearings to withstand thermal cycling and mechanical stresses in cement and mineral kilns. DUORED units for rotary kilns include combined dip and forced lubrication, with separate oil supply modules (pump, cooler, filters, monitoring) mounted on a common base frame for reliable, long‑term operation.
Flender’s vertical mill drive portfolio addresses diverse comminution needs:
KMP Series offers 17 sizes with operational torques up to 530,000 Nm, optimised tooth geometry, bearing selection, and rigid housings for coal and raw meal grinding, backed by 4,000+ references and global service.
KMPS Series targets medium to high power (up to 4,000 kw) raw meal, clinker, and slag grinding, featuring fully hydrostatic tilting‑pad thrust bearings, optimised gear tooth geometry, and extraordinary housing stiffness for extended service life.
KM2P Series combines a bevel‑gear stage with two planetary stages, supplying outputs from 2,000 kw to 9,000 kw, transmission ratios of i = 31 to 56, and compact design with full hydrostatic thrust bearings for clinker and slag mills.
KMPP Series (bevel‑planetary) offers 36 sizes, gear stages 2–3, ratios up to i = 60, and power ratings up to 8,000 kW in a highly compact package, featuring optimized gear geometry and high housing rigidity for space‑constrained cement mill installations.
The portfolio of FLENDER gear units ranges from universal standard gear units through application-specific gear units to customer-specific solutions in nearly every sector of raw material production, industry, and further processing. This range comprises helical and bevel-helical gear units, single-stage and multi-stage planetary gear units. Thanks to the different gear unit types and designs, the series offers an almost unlimited variety of designs in a torque range from approx. 2,000 to 2,600. The modular system enables extremely short delivery times. The main add-on parts are already included in the standard range, which means that adapting a gear unit to the customer’s requirements does not affect the delivery time.
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