Intech Power-Core Thermoplastics Engineering Blog

Low inertia Power-Core spur gear increases caplet machine output

Posted by Simon Barrell on Jul 27, 2010 2:18:00 PM

One of our customers, who manufactures packaging machines for the pharmaceutical industry to produce caplets, sought to improve its competitive standing by eliminating the need to lubricate the 16” cast iron main drive gear and replacing it with a lubrication free Intech Power-Core™ gear.

Upon installation of the lubrication free Intech gear, the engineers ramped up the output to 600 caplets per minute (cpm), the industry standard, and discovered that there was no vibration previously experienced with the heavy cast iron gear. Encouraged by the performance of the low inertia Intech Power-Core™ gear, they increased the output to 700…800…, all the way to 1200 cpm. Even at this speed the machine was running smoothly and without vibration.

This was in contrast with all the previous experience using the cast iron gear which reached its critical RPM around 700 RPM, at which point the machine shook violently, and the reason why the output had been established at 600 cpm.

The customer settled on an output of 800 caplets/min as a standard for the company’s brand, a 25% increase over competitive machines. The first reward came shortly after introduction of the new machine. A company producing caplets used in automotive air bags sought to increase its capacity by 2400 caplets/min. Our customer was able to satisfy that demand with three machines that don’t require lubrication, where all its competitors quoted four machines that required constant lubrication and frequent shut down for maintenance.

Low inertia often becomes the dominant, albeit unexpected benefit of changing to self-lubricating Power-Core™ gears. The main drive in the DaVinci surgical robot is another good example.

Low Inertia Spur Gear Installed in Caplet Machine

Tags: Power-Core gears, vibration, self-lubricating gears, low inertia, machine speed, packaging machine, Spur Gear

Double-rowed Power-Core drive sprocket in packaging machine

Posted by Simon Barrell on Apr 19, 2010 5:20:00 PM

In food industry applications lubrication is always an issue, so for a packaging machine we designed a composite double-rowed drive sprocket machined from Intech Power-Core™ material with a SS core that prevents abrasion on the steel chain, even at high operating speeds.

This chemical resistant sprocket is corrosion proof and ensures that no lubricant is required which could contaminate the food.

Double rowed drive socket
Double rowed-drive sprocket used in a packaging machine







One drive sprocket is used for two different chain circuits, and this component provides an integrated solution with a cast-in stainless steel hub to securely attach both sprockets to the shaft.

Intech Power-Core™ sprockets are available with or without metal core. The material’s properties lend themselves to superior wear characteristics of the sprocket teeth. Intech Power-Core™ sprockets do not wear out the chain, reduce noise and absorb shock and vibration.

Tags: Power-Core, reduce noise, reduce shock, reduce vibration, stainless steel, drive sprocket, packaging machine, corrosion proof, wear characteristics