Coperion Extruder Gearbox Repair | 429kW Rated Power, 11.5 Nm/cm³ Torque | Dyno

We can customize gearbox for your twin screw extruder, but also we can repair, maintain and replace of the same type transmission gearbox. We have already repaired and replaced numbers of gearbox made by Germany and Japan twin screw extruder manufacturers, inculding W.P, Coperion, Toshiba, JSW, KOBE, Leistritz., Maris, KOBE, PIV, EISENBEISS, etc.

• Free inspection & failure diagnosis
• Original-grade SKF/Timken bearings & seals
• Full-load dyno test with vibration analysis
• Repair in 4–6 weeks, 30% less than new gearbox cost
• 12-month warranty on repaired gearbox

“We’ve opened hundreds of Coperion gearboxes. Most failures start with the same symptoms — unusual noise at the thrust bearing, rising oil temperature, or shaft play beyond 0.15mm. One customer was quoted $85,000 and 14 weeks for a new gearbox. We diagnosed the exact damaged gear set, replaced the high-speed shaft and bearings, and ran a full-load dyno test. The gearbox was back on their ZSK line in 5 weeks, at less than half the cost. That’s what we do.”

Problem: A compounder in Turkey experienced severe vibration and loud knocking from their ZSK70 gearbox. Production had to be stopped completely.

Our Process: We performed a full teardown and discovered a cracked bearing cage on the high-speed shaft. The entire bearing set was replaced, and the shaft journal was re-ground to original specifications. After reassembly, we ran a full-load dyno test — vibration measured just 0.8 mm/s at rated power.

Result: The gearbox was reinstalled and has now run for over 8,000 hours without a single issue. The customer saved over $40,000 compared to buying a new replacement gearbox.

“Fast diagnosis, detailed report, and the gearbox came back running smoother than before. The dyno report gave us total confidence to restart the line immediately.”
— Maintenance Manager, Italy

• Damage Mapping: We ultrasonic-clean every part, then map tooth contact patterns on a Gleason tester to identify root cause — not just replace obviously broken parts.
• Critical Replacement Parts: All bearings (thrust, radial) replaced with SKF or Timken P4 precision class. Oil seals upgraded to Viton for higher temperature resistance.
• Reassembly to OEM Tolerance: Shaft end play set to 0.05–0.10mm, gear backlash within 0.20–0.30mm depending on model — exactly matching Coperion factory specs.
• Full-Load Dyno Test: We run the repaired gearbox at rated 429kW and 11.5 Nm/cm³ for 4 hours, monitoring vibration, temperature, and noise. You receive a signed test report before shipping.

• ISO 9001 certified repair center
• Technicians trained on Coperion gearbox assembly procedures
• Partner workshop for several European compounding equipment brands
• We are the gearbox repair partner trusted by compounders serving automotive OEMs in Germany, Italy,

• Performance level: same as German Flanders, Austria EssenBas, W&P, Berstorff and Leistritz, JSW, Toshiba;
• High torque: up to 15Nm/cm3
• High precision: bearings on output shaft 2 without load, the accuracy keep the same for a long time;
• Long service life: up to 72000 hours (10 years);
• High speed: max. 1750rpm/m;
• High quality: small screw clearance reduce material reflux, residence time in barrels and excessive shear;
• High efficiency: with our gearbox, the output is 1-2 times larger than the same size low torque extruder;
• High allocation: brand of bearings are Sweden SKF and Germany INA; oil seals are imported from Germany.

A: Send us a video of the noise and a photo of the gearbox nameplate. We’ll give you a preliminary diagnosis within 48 hours. If it can be repaired, we’ll issue a free inspection service order.

A: We can reverse-engineer and manufacture new gear sets. Even if teeth are completely stripped, we make new gear pairs using the same material and heat treatment as the original. As long as the housing isn’t cracked, repair is usually possible.

A: We use bearings and seals of the same brand and specification (SKF, Timken, etc.). For gears and shafts, we manufacture in-house to OEM drawings or reverse-engineered profiles. You get equivalent quality at a significantly lower cost.

A: Standard repair time is 4–6 weeks. If you need it faster, we offer a 3-week express service for an extra fee. We also keep stock of common gear sets, which can shorten turnaround even more.

We are dedicate to develop, design, and manufacture co-rotation, counter-rotation parallel twin-screw extruder production line. Our extruders have the advantages of “high torque, high efficiency, low energy-consumption, high price/performance ratio, long service life ” (designed service life of gearbox as long as 72000 hrs). We keep the same step with the most advanced extruder manufaturers in the world.

We can supply :Twin screw extruder production line;
High torque gearbox;Automatic long fiber reinforced thermoplastic composites (LFT - D) production line;Counter-rotation parallel twin screw extruder;Differential concentration mixer;
Repairing and machining large parts; Design, machine all of screw elements on Japan and Germany extruders.