It was an amazing opportunity to connect with industry leaders, explore cutting-edge innovations, and solidify MAAG GEAR’s position at the forefront of mining technology.
We proudly presented our comprehensive portfolio of advanced technologies, highlighting our unwavering commitment to driving innovation in the mining sector.
A special thank you to our partner, @TMSA, for their outstanding cooperation and teamwork in promoting our products across the CIS market. @Artem Laptev, MAAG Gear's Regional Sales Manager said " Your collaboration made this experience even more rewarding!"
Looking forward to many more successful ventures together! 


Back from Kazakhstan - Mining and Metals Central Asia 2024

We’re thrilled to share the success of this incredible event!

Mark your calendar for Cemtech Europe 2024 at Hilton Warsaw City Hotel, Poland 29 September - 2 October, 2024. Come and visit us at Booth No. 14 to gain exclusive insights from our experts on our exceptional, industry-leading range of MAAG products in the cement market.
Don't miss this opportunity to network with industry leaders and discover how our innovations can elevate your business.
Looking forward to connecting with you there!


MAAG Gear at Cemtech Europe 2024 at Hilton Warsaw City Hotel 29 September - 2 October, 2024.

MAAG Participation at Cemtech Europe 2024 

As operators look to increase equipment capacity, the key is to ensure long-term reliability that guarantees continuous kiln operation. There are several challenges. Whereas machine design is often the limiting factor for large ball mills and roller presses, it is the drive systems that require focus in vertical roller mills (VRMs). Placing silos before and after the kiln can reduce short interruptions in the milling processes, but long standstills caused by unexpected mechanical failures are difficult to avoid.

Reliability of VRMs depends on the drive system, the grinding system and the operational behaviour of the mill. To help lower initial cost investments aimed at preventing downtime, particular attention must be devoted to the drive system and critical grinding components, such as roller and table.

The rollers and the grinding table are exposed to high abrasive wear depending on the feed material properties, the product fineness, and the combination of rollers and table materials. At regular intervals, therefore, the table and roller wear liners must be exchanged or repaired by surface-layer welding.

Without the natural redundancy of an approach with two mills in parallel, flexibility is key. The OK™ mill has individual roller arrangements with swing-out mechanisms to facilitate maintenance or replacement of the rollers. In the case of mechanical failure, the mill can easily operate with fewer rollers. The only requirement is that the remaining rollers are uniformly distributed around the table circumference and that they are all the same size. Production can then continue, albeit at a reduced rate, to minimise operational disruption.

Impressively, the OK mill can achieve 60 to 70 percent of nominal output with half of its rollers out of service.


Conventional drive systems typically consist of a switch-gear to connect the drive motor to the electrical grid. The transformer converts the grid voltage to the motor design voltage and protects the equipment from voltage peaks. A rotor starting device and a highly flexible coupling connects the motor and gearbox.

Yet there are limits to such a system. The bevel stage in the gearbox, primarily used to redirect the rotating movement from the horizontal motor shaft into vertical direction of the grinding table, limits power capability. For design power of up to approximately 9,000kW, this can be overcome by increasing the gear ratio in the following planetary stage, which keeps the bevel stage size within feasible dimensions. However, this does not fulfil mill requirements and a further increase in drive power requires larger dimensions, especially the diameter of the bevel wheels. This decreases the overall reliability of the drive system. Conventional gear units cannot operate VRMs with higher design power. The drive system for these applications is based on two main principles: partition of power to several drive units and elimination of the weakest element in the drive train.


By separating the drive power, large VRMs can provide the required torque with multiple motors. The motors are designed either as individual drive assemblies containing their own motors, couplings and gearboxes or as small vertical motors, integrated partially into the gear casing and connected to a central toothed wheel inside the gearbox.

As a result, power distribution bevel stages are considerably smaller or, in vertical motors, completely eliminated. The drive systems are built so that they can operate with fewer motors in the case of malfunction or maintenance. This means that operation at a reduced production rate can still occur, minimising production losses during scheduled maintenance. This has the effect, however, of increasing complexity of the power distribution between the main switch gear and the motors and also increasing maintenance effort.

In addition to the main switch gear, each motor needs a separate circuit breaker and a motor control cabinet to allow operation with a reduced number of motors. In order to provide uniform torque to the common central wheels, the load and speed of each motor is synchronised by either a variable frequency converter or a highly flexible or fluid coupling. During start-up, when the mill is running at full speed with fewer motors, the timing of the connecting additional motors is essential to prevent torque peaks.


The integrated drive system in the VRM replaces the bevel stage with one vertical motor built into the gear casing. While this does not affect the power distribution, compared with the conventional system, the overall dimensions of the motor must be adapted to the available space for a bevel stage in a conventional gearbox. Otherwise, costly design changes of the mill support and foundation are required. 

A design study comparing different motor types showed that meeting space requirements are only possible with a synchronous motor with permanent magnet excitation and a single coil stator. To operate such type motors, variable frequency converters are necessary. Integration also makes special cooling necessary, because air-cooled motors do not reach the required power density.

For example the motor in MAAG® Gear’s CEM Drive includes special cooling tubes in the stator arrangement. This provides optimal flow of the cooling media and enables the use of gear lubrication oil in the motor cooling circuit.


Despite the challenges associated with large VRMs, there are important benefits to having an integrated drive system embedded in the design. Power distribution, such as that in a partial-load system, is not required and the number of rotating parts is kept to a minimum. The variable frequency converter allows the operator to adjust the mill table speed without time delay and to influence the grinding process individually when grinding different product in the same mill or as feed quality changes over time.

The global trend towards single-mill cement plants is unquestionable. With civil construction cost savings, higher throughput and lowered maintenance costs, the use of single large VRMs for cement and raw grinding is the optimal choice. The sheer size requires powerful, large-scale drive gear systems. 

Larger gear drives for larger vertical roller mills

Man standing before large vertical roller mills

Key Testing Parameters for the WPU-12/TS1 Gearbox

During the test run, we carefully monitor and record multiple critical parameters

Oil Inlet and Outlet Temperature: monitoring these temperatures ensures the cooling system is functioning correctly, and that the gearbox is adequately lubricated.

Bearing Temperatures: Axial Thrust Bearing - Roller Bearings - Temperature control is crucial to prevent overheating and ensure smooth operation of the bearings, which are critical for load distribution and reducing friction.

Oil Flow, Distribution, and Pressure: proper oil flow and pressure are essential for maintaining lubrication and preventing metal-to-metal contact, reducing wear and tear.

Vibrations: measuring vibration levels helps identify any bearing problems, imbalance or misalignment in the gearbox components, which can lead to premature failure.

Input Speed: verifying that the input speed matches the design specifications ensures that the gearbox will operate efficiently when integrated with the motor.

Power Loss: calculating power loss helps in understanding the efficiency of the gearbox and identifying any areas of improvement in energy transmission.

Dynamic and Static Oil Film Thickness: this measurement is vital for evaluating the lubrication quality between moving parts (thrust pads and output disc) and preventing direct surface contact.

Run-Out of Connecting Flange: checking the run-out ensures the alignment and precision of the gearbox assembly, crucial for minimizing vibration and wear.

Run-Down Time: measuring how long the gearbox takes to come to a complete stop after shutdown helps assess the internal friction and condition of the components.

Test conditions for accuracy and consistency:

The gearbox undergoes a full-speed, no-load test for 2 hours to simulate real-world operating conditions.

Driven by a variable-speed electrical DC motor, we can precisely control and measure the gearbox's response to different speeds.

The test uses a workshop lube oil unit with ISO VG 220 VCI oil to ensure proper lubrication.

Lube oil pressure is maintained at a minimum of 2.8 bar (low pressure) and 10 bar (high pressure) to simulate various operating scenarios.

Oil flow rate is kept at 140 l/min under low pressure to ensure optimal lubrication throughout the system.

At our workshop, every gearbox undergoes a rigorous test run to ensure it meets the highest standards of performance and reliability. Today, let's dive into the details of the test run process for the WPU-12/TS1 gearbox.

Gearbox test run: ensuring reliability and performance

Today, let's dive into the details of the test run process

It gave us a platform to showcase how our CMS can be a game-changer for industries:

Optimize Daily Operations: understand the value of real-time data in enhancing daily workflows.

Save Money: efficient maintenance means reduced downtime and operational savings

Prevent Breakdowns: proactively identify potential issues before they become costly problems.

Our talented team members, Marli and Roger, delivered an insightful session, and we were thrilled to see an enthusiastic audience with participants tuning in from all over Brazil, representing all CSN factories! 


MAAG Gear Invited by CSN for a virtual presentation on our Condition Monitoring System

📅 Save the date for September 17-19, 2024, and join us at Mining and Metals Central Asia 2024, which will be held in Almaty, at the Atakent IEC for 2 days of innovation, networking, and insightful discussions.
📍Visit us at booth Booth № 312 - pavilion № 11,  to see how MAAG is leading the future of mining with true innovation! 

Join us at Mining and Metals Central Asia 2024, in Almaty, at the Atakent IEC. September-17-19-2024 

MAAG Participation at Mining and Metals Central Asia 2024

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David Almond - Business Development Manager, Mining


David Almond joins us as the Business Development Manager for Mining, bringing a wealth of expertise and experience to the role. David will be focusing on expanding our presence in the mining sectors of North America and South America. His extensive background and dedication to the industry make him a perfect fit for MAAG Gear as we continue to grow and innovate. David's insights and strategic approach will be instrumental in exploring new frontiers and opportunities within the mining industry, further solidifying our leadership in the supply, maintenance, and service of large industrial gears.

John Jespersen - Business Development Manager, Iberian Peninsula

We are equally excited to welcome John Jespersen, who joins us as the Business Development Manager for the Iberian Peninsula. John's profound knowledge and commitment to excellence will be invaluable as we enhance our operations across this region. With John's leadership, we anticipate significant advancements in our services and solutions, driving innovation and achieving new milestones. His role will be crucial in maintaining and expanding our footprint, ensuring that MAAG Gear remains a leader in the industrial gear sector.

As we continue to expand our team with exceptional talent like David and John, we are more optimistic than ever about the future. Their contributions will undoubtedly help us reach new heights and achieve our ambitious goals. Welcome aboard, David and John! We look forward to your invaluable contributions and the bright future ahead for MAAG Gear.

Stay tuned for more updates and details. Follow us on LinkedIn, FB and Instagram!

We are thrilled to announce the newest members of the MAAG Gear family. Please join us in welcoming David Almond and John Jespersen to our team!

Exciting New Additions to the MAAG Gear Team: Welcome David Almond and John Jespersen! 

Two persons next to each other that have been hired by MAAG

The Polish MAAG GEAR team successfully completed the Elbląg Marathon 444 this past weekend. Covering an impressive 444 km around the former Elbląg Voivodeship, our dedicated team braved challenging weather conditions to cross the finish line with smiles after 19 hours.

On the same day, a second marathon took place with 15 participants embarking on a 120 km bike trip called "Giro Sniardwy." It was truly a sportive day where all colleagues gave their maximum effort to have fun and engage with each other.

Additionally, we participated in a city run (10 km) and were proud to be the main sponsors of all the races. Our involvement not only showcased our athletic spirit but also our commitment to community engagement and support for local events.

In Milan, we celebrated an incredible experience by participating in a charity run alongside the non-profit association 'Robin's Boys' (I ragazzi di Robin). They invited our MAAG GEAR team to join the BRUTAL SUPERHEROS RUN marathon, an event that emphasized the spirit of heroism and community.

BRUTAL Marathon Team in Italy at finish line

A special thanks to our team and everyone involved. As Batman said, "Anyone can be a hero, even a man doing something as simple and reassuring, as putting a coat around a young boy’s shoulders to let him know the world is not over" (The Dark Knight). This quote encapsulates the spirit of our participation and the positive impact we aim to have in our communities.

We look forward to seeing everyone at the starting line next year!

June was a vibrant period for MAAG GEAR, filled with sportive and social events that brought our team closer together. Our participation spanned various activities, including running and biking marathons in Elbląg and a walking race in Milan.

A Month of Sportive and Social Triumphs

Our MAAG® MAX Drive has been put to the test and has completed more than 1000 hours of operation in a hugely successful installation! Holding the Guinness World Record for the largest Vertical Roller Cement Mill in the world, The installation at Shah Industries in Bangladesh is proudly driven by the MAAG® MAX Drive!  With a rated power of 11656 kW, an input speed of 1484rpm, an output speed 18.3rpm and weighing in at 300 tons , MAX Drive is rising to the occasion! Just imagine the difference that this gearbox can make in your plant!


MAAG® MAX Drive - Guinness World Record

Located in Morocco’s El Jedida province, the new Ouled Ghanem cement plant is being co-delivered by Société Général des Travaux du Maroc (SGTM) and FLSmidth for NOVACIM S.A. The 3,600 tpd plant will ultimately produce 1.1 million tons per year of clinker and 1.4 million tons per year of cement for the fast-growing North African market.

The plant features the first MAAG IronDrive gear unit to go into commercial operation globally. Full scope of the contract includes engineering and supply of a full-range of equipment: from crushing to packing and load-out, supervision of commissioning, and training the local workforce.


The MAAG® IronDrive gear unit is designed with one goal in mind: to cut operating costs. It is reliable and flexible: able to be used in all types of mills (up to 9000 kW) and plant arrangements. Meanwhile, its bevel gear-planetary gear arrangement is designed to deliver highest transmittable torque to the VRM at the highest efficiency. By the end of 2022, the unit had been delivered to site, installed, and MAAG experts were on site to assist with trials.

When installation and commissioning a new equipment design, challenges are always expected. But not at Ouled Ghanem. “We expected some problems, as we have changed a lot in the design during project execution,” said Michał Zaskiewicz, Head of Product and Supervisory Service, Grinding & Gears, at MAAG. “Here there were no surprises. Execution went smoothly and performance met expectations.”

MAAG IronDrive gear unit is also designed operate reliably, ensuring high availability.

 For example, the thrust bearing for the grinding table provides dependable output, while internal emergency shoulders limit tilting of the table.
When maintenance is needed, the MAAG IronDrive gear unit incorporates a range of features to enhance accessibility and safety. Larger manholes improve access to the interior compared to its predecessor units, while the MAAG lubrication concept with external oil tank improves overall efficiency and allows access to the bevel stage at any time, without having to drain the oil. The unit also features a special mechanism allowing adjustment of the teeth contact on the bevel gear, without removing the whole gear unit from below the mill.


The Ouled Ghanem unit is also equipped with full condition monitoring system and torque-measuring system, and 

it’s covered by a MAAG® mySentinel Advanced service agreement – a package that supports gear operators to plan, budget, and execute maintenance activities and includes online condition monitoring service.


“The new unit is equipped with a range of sensors that deliver real-time data on mill performance to the operator,” said Zaskiewicz. “It’s one thing to have this data; it’s another to be able to interpret it. Which is where our monitoring services come in. Our gear specialists monitor the condition of the gear and provide detailed analysis, with additional maintenance and spare part suggestions, to ensure maximum equipment availability is achieved.”


A positive premier for the IronDrive gear unit

As part of the contract, MAAG is providing training to local operation and maintenance engineers. The training will cover how to operate the gear unit, as well as how to identify potential issues early and how to react to prevent them escalating into more serious incidents.

“The customer had some understandable concerns about installing a new design of gear unit. And we certainly expected some surprises along the way,” concluded Zaskiewicz. “But despite it being the first installation of its kind, it was quite straightforward! The gear unit works as expected - and with the training and condition monitoring agreement in place, we can continue to ensure it continues to work well as the plant moves to full production.”

First cement was delivered at the new Ouled Ghanem cement plant near El Jadida, Morocco, in late 2022. The plant includes the first installation of a latest-innovation MAAG® IronDrive gear unit.

New-generation MAAG® gear unit starts work at Ouled Ghanem cement plant

MAAG GEAR Services

Gear units are often pushed to their limits and are subject to extreme wear and tear over many years. To keep your gear unit working effectively, you need high-quality and high-value solutions and services. Our service and maintenance products are provided by highly experienced gear specialists, who work with you to achieve optimal equipment availability and uninterrupted production. With our services, maintenance costs become more predictable. We also share knowledge with your maintenance staff, helping you to keep your gear unit in optimal condition. We offer a complete range of gear overhaul and repair activities for all parts, including rotating parts, bearings, and designed components.

MAAG® GEAR Services

Across the northern hemisphere, the first quarter of the year is known as ‘shutdown season’. Naturally, when so many cement plants schedule their maintenance shutdown for the same period of time, it's difficult to allocate resources to everyone who needs them.

This is further complicated by late bookings, by which point plants may find themselves disappointed and have to look elsewhere for their gearbox inspection service.


The difficulty is, of course, that no one is as well placed as the OEM to assess the health and performance of your gearbox. We know the equipment – and we have the tools to conduct a full vibration analysis. Plus, with references around the globe and more than a century in the field, we bring a depth and breadth of experience to every inspection that no other service provider can offer.


To take advantage of that experience, why not move your gearbox inspection outside of those busy months? Pulling it out of the shutdown season ensures you get the OEM-quality inspection your equipment needs. It doesn’t cost you any more than it would in Q1 and in fact enables you to spread the cost of maintenance through the year. More importantly, it doesn’t add any further disruptions to your process, since the inspection can be scheduled to coincide with a regular mill shutdown. Best of all, you get access to our people and equipment to ensure a comprehensive analysis that prevents serious issues from going unnoticed.

We conduct gearbox inspections for all MAAG® gearboxes, including Symetro, WPU, CPU, WPV gearboxes. These two-day inspections include analysis during operation as well as at standstill and are followed up by a full report on your gearbox condition, together with any recommendations we might have for optimisation. Vibration analysis is included as standard – an insight that helps to inform both maintenance and operational strategy. The full process varies from gearbox to gearbox, but in general includes:

Condition of tooth surfaces and tooth contact

Your gearbox is central to your process. Give it the attention it deserves to ensure optimum performance and continued, reliable operation.


If you would like to secure MAAG specialists for your gearbox inspection and ensure you benefit from the insights provided by vibration analysis, book now. 

Vertical roller mills and ball mills are regularly taken out of operation for routine maintenance. Some plants even shut their mills down every week. Yet, gearbox inspections are typically scheduled for the annual maintenance shutdown when resources are stretched. This is making life harder than it needs to be for all involved. Let’s simplify things. Consider scheduling your gearbox inspection to later in the year when you can access the expertise and tools you need. This way you can be sure you’ll have access to the most experienced service technicians, equipped with all the tools they need to get the job done.

Schedule your gearbox inspection 

The MAAG® CEM Drive is the most efficient drive system for large vertical roller mills. Capable of a power range from 4000 to 14 000 kW, this 2-stage planetary gear system with integrated electric motor enables our customers to reduce power loss by more than 20% for a CO2 savings of around 1 tonne/day.

MAAG® CEM Drive

Our standardized MAAG® PPU Gear unit is originaly designed for hydraulical roller presses. But the configurable design of this classic planetary gearbox enables it for many more application in nearly all industries.

MAAG® GEAR PPU gear unit for hydraulic roller presses

Our MAAG® CPU Gear unit represent the classic central drive for ball mills. With it's two-stage planetary gear arrangement it delivers highest productivity for your ball mill.

MAAG® GEAR CPU Gear unit for ball mills

The gearing and bearing arrangement are the most important components, which was taken over from the existing design. The driving torque is transmitted via a flexible coupling from the motor shaft to the input shaft of the gear unit. The first gear stage transmits the power into the intermediate shaft, the centre piece of the mechanical torque split. Two helical gearings with opposite helix angels are located on both side of the first gear stage and mesh the output shafts containing self-aligning pinions. Due to girth gear misalignment, unbalanced torque on the two output pinions will cause uneven axial loads in the helical gearings of the intermediate shaft and it moves in the direction of the less loaded side, restoring the balance of torque. The special toroidal bearings installed in the intermediate shaft support the large capacity of axial movements. With this feature our MAAG LGDX gear unit can compensate larger misalignments than any other comparable gearboxes.

Flexibility and increased longevity by design


The redesign is also used to increase the installation flexibility of this unique gearbox to almost every imaginable position and setup. Our engineers solved this challenge with a simple but smart solution. We decoupled the gear casing from the foundation frame and used the opportunity to configure the casing symmetrical to the horizontal as well as to the vertical. Now, the very same MAAG LGDX Gear Unit can be installed at the centre line or 40° below your ball mill. The latter reduces construction costs by cutting down on foundation height. In addition, the low, compact foundation is less sensitive to vibration, which contributes to the continued smooth operation of your ball mill. As the foundation frame is not an integrated part of the gear housing, design adaption to existing foundations are very easy to be implemented and support one-to-one replacements of existing gears of varying types and brands.

Center line and 40 degree position compared

The separated foundation frame and the symmetrical casing support the high flexibility of the MAAG LGDX Gear Unit.

Finally, our gear unit comes with teeth grounded on both flanks, simplifying spare part management. In case of dual arrangement, where two gear units are installed on both side of large ball mills, one spare unit fits for both sides. And in case of worn-out teeth you can simply turn the MAAG LGDX upside down and operate on the back flank of the gearing, thanks to the symmetricity of the housing. In simple terms, it means that the spare gearing is already included in the original gearbox.

Auxiliary system rounds up the proven design


Based on two decades of operating experience and valuable customer feedbacks, we know that the most limiting factor for bearing and gearing lifetime is related to dusty environment around a ball mill. Clean and fresh lubricants are essential to ensure high reliability and durability, especial for the highspeed bearings and gearing.
For this, our engineers found the perfect solution. Key feature is the sealing of gearbox internals from the dusty environment. A sheet metal covering separates the highspeed gearing and bearings from the girth gear and keeps the internals in a clean and dust-free area. Finally, with two lube oil units we provide a closed lubrication circuit for the gearbox and an open circuit for the girth gear.

In case of replacement projects, we use the existing oil unit to lubricate the girth gear and in addition we supply a new small lubrication unit to feed the gear internals.

explanation of the LGDX and where the oil is located


Our redesigned lateral gear drive for ball mills, the MAAG LGDX Gear Unit boost your ball mill to the next level of performance. Technical key features like the mechanical torque split, the large capacity to compensate girth gear misalignment and the sealed lubrication system provide the highest available reliability. The symmetrical casing with separated base frame supports every possible setup, including a dual arrangement for large horizontal mills. Together with the grounded back flank of toothing this gear unit includes a built-in spare gear set.

“With the MAAG LGDX gear unit and a minimum of effort and down time for the gear exchange you bring your old mill drive system back to state of the art”

The Challenge: Redesigning a well-proven system is a difficult task for engineers. But our product specialists checked the strengths and weaknesses of the initial design and combined the benefit with new requirements to build the unique three-stage spur gear MAAG LGDX Gear Unit.

LGDX lateral gear drive for ball mills

Designed to drive comminution machinery in cement and minimg processing, our MAAG® WA Gear unit delivers impressive performance and reliability for your horizonal mill.

MAAG® GEAR WA gear unit for ball mills and kilns

Our MAAG® WPV Gear unit with the bevel and double-planetary gear arrangement drives your vertical roller mill reliably. With the unique torque split highest power output are possible in a compact design

MAAG® GEAR WPV gear unit for vertical roller mills

The robust design of our two-stage bevel planetary MAAG® WPU Gear unit delivers dependable operation for your vertical roller mill.

MAAG® GEAR WPU gear unit for vertical roller mills

MAAG® GEAR Bevel Sets 

Gears for crushers

MAAG® GEAR CPU Gear Unit 

Gear pinions

MAAG® GEAR Girth Gear

MAAG® GEAR LGDX Gear Unit 

MAAG® GGL Girth Gear lubrication

MAAG® GEAR PPU-C Gear Unit 

MAAG® GEAR Symetro™ Gear 

MAAG® GEAR WA / Temperex Gear

Gears for horizontal mills 

Gears for kilns

MAAG® GEAR KA / KB / Temperex

Gears for other applications

MAAG® GEAR PPU Gear Unit 

Gears for roller presses

MAAG® GEAR CEM Drive

MAAG® Iron Drive Gear Unit

MAAG® GEAR MAX Drive System

MAAG® GEAR WPU Gear Unit 

MAAG® GEAR WPV Gear Unit 

Gears for vertical roller mills

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Our service and maintenance products are provided by highly experienced gear specialists, who work with you to achieve optimal equipment availability and uninterrupted production. With our services, maintenance costs become more predictable. We also share knowledge with your maintenance staff, helping you to keep your gear unit in optimal condition. Recommendations and engineering solutions for all type of gears including emergency help.

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