CPU-65 Gearbox Overhaul at InterCement Ijaci Plant

In January, MAAG Gear successfully supported the overhaul of a CPU-65 planetary gearbox at InterCement’s Ijaci cement plant, one of the largest and most powerful gear units operating at the site.

The project demonstrates how expert field service, long-term partnership, and technical continuity are essential to ensuring reliable operation in demanding cement industry applications.

A Critical Planetary Gearbox for Cement Production

The CPU-65 planetary gearbox involved in the overhaul is a key asset for the Ijaci plant, supporting continuous and high-power operation. Its main specifications highlight the scale and complexity of the intervention:

• - Weight: approximately 119 tons
• - Power rating: 7,300 kW
• - Application: critical cement plant drive

Given the importance of this gearbox for plant reliability, the overhaul required careful planning, precise execution, and close coordination between MAAG Gear and InterCement’s maintenance team.

MAAG Gear Field Service and Customer Collaboration

The success of the CPU-65 gearbox overhaul was driven by strong collaboration between all parties involved.

On the MAAG Gear side, the project was supported by @Marli Pequeno, Regional Sales Manager, whose early customer visits—starting more than a year before the intervention—helped build a solid technical and organizational foundation.

This groundwork was further strengthened thanks to the continuous involvement of @Roger Wagner, Customer Service Project Manager, who provided support during both technical meetings and service activities. In addition, @Peter Gunsch, MAAG Gear partner, contributed by ensuring on‑site coordination throughout the overhauls.

On the customer side, the Ijaci maintenance team played a decisive role. Rafael Gomes , Mechanical Maintenance Coordinator, was responsible for that overhaul at Ijaci plant.Their professionalism, technical competence, and commitment ensured smooth execution and adherence to safety and quality standards.

Continuity of Expertise Over More Than 20 Years

More than 20 years later, MAAG GEAR involvement in the overhaul provided valuable continuity of knowledge and a unique learning opportunity for the Ijaci maintenance team, combining historical insight with current best practices in gearbox service and maintenance.

Customer Testimonial from InterCement Ijaci

As Rafael Gomes, commented following the successful completion of the overhaul:

“In January, we successfully completed the overhaul of the MAAG CPU-65 planetary gearbox, one of the largest and most powerful units in our plant at Ijaci. Weighing approximately 119 tons and delivering 7,300 kW of power, this major reducer required innovative approaches and a highly coordinated effort from our internal team and external partners.

The accomplishment of this project highlights the strength, competence, and commitment of everyone involved.

Reliable Gearbox Overhauls Through Long-Term Partnership

This CPU-65 gearbox overhaul at the InterCement Ijaci plant highlights the value of long-term partnership, expert field service, and engineering excellence.

MAAG Gear is proud to support cement producers worldwide with gearbox service solutions designed to ensure reliability, performance, and operational continuity over decades of operation. We look forward to continuing our collaboration with Inter Cement on future service and maintenance projects.