Driving Innovation: MAAG Gear Powers the World’s Largest Calcined Clay Plant at CBI Ghana

MAAG Gear has played a key role in one of Africa’s most advanced cement industry initiatives: the development of the world’s largest industrial-scale flash calciner for clay at CBI Ghana, located in the Tema Free Zone Enclave.

With the installation of the company’s state-of-the-art MAAG LGDX lateral gear unit, the plant benefits from a highly efficient, reliable and sustainable drive solution that directly supports low-carbon cement production.

This project also attracted international attention: International Cement Review dedicated a full technical feature to it in the November 2025 issue. You can download the complete article here.

A New Era of Sustainable Cement in Africa

Africa’s cement industry is undergoing rapid transformation as governments and private stakeholders increase their focus on sustainable technologies and local production capacity. Ghana stands at the forefront of this evolution.

Developed in partnership with Heidelberg Materials, the calcined clay project at CBI Ghana marks a significant milestone. With an annual production capacity of over 400,000 tonnes, the new facility helps reduce dependence on imported clinker while substantially lowering CO₂ emissions.

The MAAG LGDX: Precision Engineering to Drive the Future

To meet the project’s demanding technical requirements, CBI Ghana selected MAAG Gear as its strategic drive technology supplier. The LGDX was the ideal choice thanks to its durability, mechanical precision and proven performance in ball mill applications.

The LGDX is a three-stage parallel shaft gearbox designed to reduce motor speed and efficiently deliver power through two output pinions. Its mechanical torque split ensures balanced load distribution, promoting stability and minimising wear.

Self-aligning output pinions automatically compensate for mill misalignment and thermal expansion, maintaining optimal tooth contact and extending equipment life.

Complementing the LGDX is the MAAG girth gear, produced from high-grade alloy steel using rolled and bent ring segments. This design provides superior fatigue and wear resistance, ensuring consistent performance under heavy loads. Over 1,000 MAAG girth gears operate worldwide, highlighting their reliability across the cement and minerals sectors.

Flexibility and Long-Term Value

A defining advantage of the LGDX is its symmetrical and modular housing, which gives operators considerable installation flexibility. The gearbox can be positioned below the mill or directly on the centreline, depending on site conditions.

Because the housing is reversible, the gearbox can be flipped to use the opposite tooth flank, significantly extending operational lifetime —by up to 40%— and simplifying logistics during future maintenance.

Clean Lubrication for Reliable Operation

Cement production environments present major challenges for lubrication systems. To address this, the LGDX features a dual-circuit lubrication design that keeps internal components supplied with clean oil, while a separate circuit lubricates the pinion–girth gear interface.

For the CBI Ghana installation, MAAG Gear implemented an extra level of fine filtration in both circuits, further enhancing oil cleanliness and protecting sensitive components. This tailored optimisation reduces contamination, limits unplanned downtime and increases overall system reliability.

Engineering for Energy Efficiency

The LGDX’s compact and lightweight configuration reduces foundation requirements, installation time and environmental footprint. Its efficient design supports CBI Ghana’s sustainability goals, while embodying MAAG Gear’s commitment to lowering energy consumption and extending equipment life across its entire product portfolio.

Smooth Installation and Commissioning

Installation of the LGDX took place in two phases. The first—lasting about a month—included positioning the gearbox and auxiliaries. The second phase, focused on start-up and commissioning, was completed in just five days.

During installation, MAAG engineers carried out precise mill alignment checks, verified girth gear run-out, laser-aligned the main motor and ensured the lubrication system was clean and stable. Commissioning under full load recorded vibration levels of approximately 2.5 mm/s, confirming long-term operational stability.

Conclusion: A Benchmark for the Cement Industry

The successful implementation of the MAAG LGDX at CBI Ghana demonstrates how strategic partnerships and advanced engineering can accelerate sustainable cement production in Africa.

With its durability, flexibility and energy-efficient design, the LGDX sets a new benchmark for modern drive technology—and the CBI Ghana project stands as a flagship example of how MAAG Gear supports customers in delivering reliable, low-carbon cement solutions.