Huge Gear Plant Under Construction in Germany

22 July 2009

Said to be one of the biggest private construction sites in Baden-Württemberg, Germany, SEW-Eurodrive’s new industrial gear manufacturing plant in Bruchsal has 450 engineers, architects, technicians. and construction workers working on location. The construction project began in January 2008 and is planned to be completed in early 2010.

SEW Eurodrive new factory in Bruchsal
SEW Eurodrive new factory in Bruchsal

With the usable space for production, logistics, office and recreation areas planned at 60,000 sqm, the new plant is equivalent to the area of nine football fields.

Planners say the production area will be 15,800 sqm and another 16,000 sqm will be dedicated to assembly. Logistics will take 12,800 sqm and the design leaves room for 7,450 sqm of office space.

The triangular shaped plant at the far left in the photo is the power plant for the factory.

Environmental approach

An integral approach is being taken to cut environmental pollution at the new plant, but it will only work if the entire life cycle is taken into account, say the building planners.

“As raw materials are becoming ever scarcer and CO2 emissions are on the rise, we must strive to use valuable resources efficiently and aim to achieve an optimum environmental balance,” says Gunthart Mau, spokesman for SEW-Eurodrive.

“The new industrial gear unit plant fulfils both these requirements.”

X Series gears
X Series gears

To ensure that CO2 emissions are reduced to a minimum, the company will install a photovoltaic system on the high-bay warehouse with a capacity of 155 kW. It is projected to generate approximately 140,000 kWh electricity a year.

Products to be manufactured

SEW-Eurodrive says it will use the new plant to expand its product portfolio in industrial gear units in the X and P series. “The market for industrial gear units offers great potential and opens up further opportunities for development in the future.” says Mr. Mau.

He says the new plant will “raise the bar in terms of innovation, process optimisation and excellent added value, with the aim of always staying one step ahead of the competition.”

A new kind of order centre is to be established, which will handle every aspect of order processing activities, from the moment the order is received all the way through to product dispatch. Sales, purchasing, order creation, production and assembly will form a single unit.

X series

The X series (shown above) is a universal gear unit series which can be optimally adjusted to the task due to finely stepped torque ratings.

P Series gears
P Series gears

The modular system concept sets offers a broad range of application options, e.g. for conveyor systems, ball mills, and agitators. Application gear units, such as for bucket conveyors, complete the range.

P series

Up to now, says Mr. Mau, it was almost impossible to order planetary gearmotors in this power class from a catalogue. "SEW´s P series products (right) are a significant step closer to achieving this ideal situation."

The gearmotor is mounted directly in front of the planetary gear unit. Couplings, intermediate flanges and adapter flanges that take up space and increase costs are a thing of the past.

P series units are available in 9 sizes, covering the 24 to 359 kNm torque range.

P gearmotors can be used anywhere where there is a need to move heavy weights at a low speed.

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