Gearbox Reliability in a
Coal Feeder Application

Recurring Gearbox Failures Disrupting Plant Reliability

A customer operating screw coal feeders was experiencing recurring, catastrophic gearbox failures, with units lasting less than two months after commissioning.

With more than 60 gearboxes installed across the site, equipment reliability was a significant concern. Frequent failures resulted in unplanned downtime, increased maintenance requirements and potential production losses.

The customer approached BI for a more reliable, long-term gearbox solution that could withstand the application’s operating demands while reducing the risk of premature failure.

A More Robust Gearbox Solution Built for Reliability

Following discussions to understand the customer’s operational challenges, BI recommended replacing the existing gearboxes with i.Mak IRAP52-IEC63 inline gearboxes.

Manufactured by i.Mak, a gearbox manufacturer with over 70 years of industry experience, the proposed solution offered a robust design with an appropriate safety factor to support the application’s operating requirements.

Beyond equipment reliability, BI highlighted the importance of reducing unplanned downtime and protecting plant productivity.

• Robust gearbox construction designed for demanding industrial applications.
• An appropriate safety factor to support reliable operation.
• Cost-effective equipment backed by a two-year warranty.
• Manufacturer support from i.Mak in Turkey.
• Access to an extensive local stockholding of gearbox spares for ongoing maintenance and support.

With Bi’s technical expertise, local product availability and after-sales support, the customer had confidence in the proposed solution.

From Repeated Failures to Improved Operational Confidence

Following the recommendation, the customer placed an order with BI Delmas for the i.Mak IRAP52-IEC63 inline gearboxes. The units were supplied and commissioned, with the first installations operating since July 2026 without any reported failures.

• Improved reliability: No gearbox failures reported since the units entered service in July 2026.
• Reduced downtime risk: Reliable operation has reduced the immediate concern of recurring premature gearbox failures.
• Lower maintenance exposure: Fewer reported failures mean less need for unplanned gearbox repairs and replacements.
• Cost-effective solution: A competitively positioned gearbox supported by a two-year warranty and local spares availability
• Customer confidence: Four i.Mak gearbox units have been supplied to date, with positive customer feedback.

THE RESULT: FOUR GEARBOXES SUPPLIED. ZERO REPORTED FAILURES.
By addressing the customer’s recurring gearbox failures with a robust, application-appropriate solution, BI helped improve equipment reliability and operational confidence.

With four i.Mak gearboxes supplied and no reported failures since commissioning in July 2026, the installation demonstrates the value of combining reliable industrial products with technical expertise and dependable local support.

BI continues to support customers with practical power transmission solutions that help keep industrial operations moving.