Constant investments in research and development, the high technical level of the manufacturing machinery, the accurate selection of raw materials and of all other components, the care for every aspect of the entire industrial process and last not least the great experience of our different teams enable us to manufacture products of high value.
The range of the Zambello group covers the following types of products:
Gearboxes for single-screw extruders,
Gearboxes for co-rotating twin-screw extruders,
Gearboxes for counter-rotating twin-screw extruders (parallel and conical ones),
Gearboxes and geared motors for electric injection presses, special gearboxes.
Gearboxes for single-screw extruders
The ZPE series for single-screw extruders places Zambello at highest level in the world as to the transmissible torque as referred to weight and dimension of the gearbox. The series of this range are very complete and go from the smallest gearbox of size 90 (for extruders with 25 to 30 mm screw diameter)up to gearboxes of size 630 (for big extruders with 300 to 400 mm screw diameter).
The high level of this range regards designing and manufacturing of toothed gears, which are completely built and tested at the Zambello factory, and also of the components which are supplied by the most important European manufacturers.
Due to the politics of the constant extension of the spare-parts stock, Zambello is able to ensure best punctuality as regards delivery times.
The ZPE range offers 3 different series:
ZPE1 for high revolutions (reduction ratio from i=2 to i=6.3)
ZPE2 for medium revolutions (reduction ratio from i=6.3 to i=28)
ZPE3 for medium and low revolutions (reduction ratio from i=6.3 to i=125).
Gearboxes for co-rotating twin-screw extruders
ZT RANGE – With a transmissible torque density up to 14 Nm/cm3 per shaft
The gearboxes of the ZT RANGE are designed for a wide range of applications and requirements, starting from the typical applications for revolutions of 300 to max. 900 rpm. to where lower revolution rates from 25 to max. 200 rpm. (ZT2, ZT3 series) are required. The range is available for centre distances from 24 mm to 200 mm. On request, also bigger versions can be built.
TST RANGE - Due to those manufacturers who need to increase the power rates of co-rotating twin-screw extruders, the TST (Twin Super Torque) series is provided with a torque distribution system, which is able to ensure a considerable increase of the output revs. (up to 1800 rpm.) and of transmissible torque density (up to 16 Nm/cm3 per shaft). The dimensions of the gearboxes of the TST range available at present go from center distances of 20 mm to 120 mm. However, at the moment bigger sizes are planned.
TST- HD SERIES (High Density) – This new series at the top level worldwide, which is able to support torque densities of more than 18 Nm/cm3 per shaft, at present is under development. For any sizes already available please consult Zambello.
Gearboxes for counter-rotating twin-screw extruders parallel and conical type
Parallel type Although the range of gearboxes for counter-rotating twin-screw extruders used for medium, high and very high torques is already very wide, Zambello updates it constantly both with new sizes of standard products and tailored gearboxes for the exacting needs of customers.
NRB series – With a transmissible torque density up to 17 Nm/cm3 per shaft
The gearboxes of the NRB range have a horizontal shape (mounting position B3), which requires a connection to the electric motor by belts and pulleys. As a matter of fact, the reduction ratios available cover a ratio up to a maximum of i=25.
ZT3 series – With a transmissible torque density up to 17 Nm/cm3 per shaft
The gearboxes of the ZT3 series have approximately the same features as the NRB series, but have a vertical shape (mounting position B7). In this case the connection between gearbox and electric motor is carried out by an elastic coupling. Due to the possibility to mount the electric motor in the U arrangement, the final result is a very compact extruder. Reduction ratios available go from i=14 to max. i=80.
TST range – The TST range (Twin Super Torque) is available in two versions: TST-H and TST- 2H. Both series offer very high performance rates.
TST- H series – With a transmissible torque density up to 20 Nm/cm3 per shaft
The gearboxes of this series are designed for exacting applications, where a high torque is required, which is transmitted by means of a single reversing unit. The connection to the electric motor is obtained by means of an elastic joint. The reduction ratios available go from i=14 to max. i=80.
TST- 2H series - With a transmissible torque density up to 22.5 Nm/cm3 per shaft
The gearboxes of the TST-2H series present the highest technical level for which these are the best worldwide for heavy-duty jobs. The transmission of the torque is obtained by means of a double reversing unit. The reduction ratios available go from i=14 to max. i=80.
Conical type As a completion of the range of gearboxes for counter-rotating extruders, Zambello proposes the new ZC3 gearboxes for conical twin-screw extruders.
At the moment the new gearboxes are available in three sizes, which are suitable for extruders having screw diameters of 55 mm, 65 mm and 80 mm.
The essential feature of these gearboxes consists of ground conical gears according to AGMA 11 - DIN 3. Like the entire range of Zambello, also the gearboxes ZC3 enable an extremely high transmissible torque.
Gearboxes and geared motors for electric injection presses
As the confirmation of the great flexibility of its products, with this new SERIES MNP3, Zambello supplies gearboxes both in standard execution and also in partially variable versions or customized ones according to the customers’ specific requirements.
The gearboxes of the MNP3 series have been specifically designed for the drive of plasticizing screws for injection presses. These are suitable for transmitting high torques by accepting also very high input speeds at very low noise levels and total performances over 95%. The great axes distance between the drive (electric motor) and the output (threaded mounting and cylinder), which consists of 3 gear pairs, avoids any problems of interference with the various machine units.
The extreme precision during grinding and checking of the gears (according to the class AGMA 11 - DIN 3) allows to match these gearboxes to very powerful electric motors at high revolutions (also over 3000 rpm) offering low dimensions and weights. For this reason, the Zambello gearbox for injection presses is of very compact and powerful construction.