New Product Development

Introduction of New Product Development

At Esenpro, innovation is at the core of our business. Our New Product Development (NPD) process focuses on engineering advanced industrial gearboxes that cater to the evolving demands of industries.

By leveraging cutting-edge design software, precision manufacturing, and rigorous quality testing, Esenpro ensures that each new product meets global performance standards. Our R&D team collaborates closely with industry experts to enhance gearbox efficiency, durability, and customization, offering tailored solutions for specific applications.

With a commitment to continuous improvement and customer-centric innovation, Esenpro’s NPD initiatives aim to deliver gear solutions that optimize performance, reduce downtime, and improve operational efficiency.!

Case Study

A leading Plastic manufacturing company was facing operational inefficiencies due to the use of hydraulic motors in its plastic blow moulding machine. The high maintenance costs, frequent breakdowns, and energy consumption were significantly impacting productivity. The company sought a more reliable and efficient solution to improve performance and reduce downtime.

Challenge

The existing hydraulic motor system posed several challenges:

High maintenance costs due to oil leakage and frequent component replacements.
Operational inefficiencies leading to unscheduled downtimes.
Excessive energy consumption, increasing overall operating expenses.
Limited torque and speed control affecting production output.

The client required a robust alternative that could provide higher torque, improved efficiency, and reduced maintenance needs while seamlessly integrating into their existing setup.

Solution Provided by Esenpro

Esenpro recommended replacing the hydraulic motor with a Bevel Helical Gearbox specifically engineered for the application.

Key features of the solution included:

High torque transmission capacity ensures smooth and efficient power delivery.
Energy efficiency reduces power consumption by up to 30%.
Compact and durable design for long-term reliability in harsh mining conditions.
Low maintenance requirements minimizing downtime and associated costs.
Seamless integration into the existing conveyor system with minor modifications.

Implementation Process

Assessment & Feasibility Study – A thorough analysis of the operational requirements and compatibility with the existing system.
Custom Gearbox Design – Engineering a tailor-made bevel helical gearbox to meet the torque and speed requirements.
Installation & Commissioning – Ensuring a smooth transition from hydraulic to mechanical drive with expert supervision.
Performance Testing & Optimization – Fine-tuning the system for optimal performance post-installation.

Results & Benefits

After the successful implementation of the Esenpro Bevel Helical Gearbox, the client reported: 35% increase in efficiency due to optimized torque transmission. Reduction in maintenance costs by 40% as lubrication issues and frequent part replacements were eliminated. Energy savings of up to 30% leading to significant cost reductions.Enhanced system reliability with consistent and uninterrupted operations. Improved productivity with better speed and torque control.

Conclusion

The replacement of the hydraulic motor with Esenpro’s Bevel Helical Gearbox proved to be a game-changer for the company. It not only enhanced operational efficiency but also reduced overall costs and increased productivity. This case highlights Esenpro’s commitment to providing innovative and high-performance power transmission solutions tailored to industry-specific needs.