Efficient ZLYJ Series Extruder Gearbox for Enhanced Productivity

◆ZLYJ Series gearboxes are designed for single screw extruder drives, integrating a high capacity thrust bearing to absorb axial screw loads. Gear elements are case hardened and precision ground to grade 6 accuracy per GB10095 standards. Ratios cover from 8 to 20 with input powers spanning 5.5 to 200 kilowatts. How it works: input rotation passes through hardened helical gear stages arranged on parallel shafts, reducing speed while multiplying torque. The front mounted thrust bearing assembly transfers screw push force directly to the housing, protecting reduction gearing from axial loading. Standard cooling coils control oil temperature during continuous operation. Solid input shaft and hollow output shaft with splined coupling sleeve suit standard extruder interfaces. ZLYJ units drive single screw extruders processing polyethylene, polypropylene, PVC, and engineering plastics across pipe, profile, sheet, and pelletizing lines.

▼Key Features

★ Modular design, high load-bearing capacity, high precision

★ Low noise, long lifespan, easy maintenance

★ Compact size, high transmission efficiency

▼Specifications

▼HelmeDrive Gearboxes Exporting-ZLYJ Series Extruder Gearbox

▼ZLYJ Series Extruder Gearboxes Typical Industrial Applications

�FAQ

Q1: How do I calculate axial thrust? And how do I know the gearbox won’t fail from it?

A:

Axial thrust is the force the screw pushes back into the gearbox. Skip this calculation and you risk bearing failure—a costly downtime.

Formula:

Fa = π × (Ds² × Ps) / (4 × 1000)

· Ds= screw diameter (mm)

· Ps= screw pressure (MPa)

Example:A 90 mm screw at 26 MPa →165 kN thrust.

The ZLYJ series is built with oversized thrust bearings. Depending on model, it handles up to 770 kN— 4 to 5 times what a standard extruder gearbox can take.

Before vs. after:

· A Vietnamese pipe extruder replaced their gearbox every 18 months due to thrust bearing wear.

· After switching to ZLYJ sized with actual thrust calculation:3+ years on the same bearings, still running.

Send us your screw diameter and max pressure. We’ll calculate the thrust and pick the right model.

Q2: How do you keep the gearbox cool when the extruder runs 24/7?

A:

Continuous extrusion builds heat. If the gearbox runs too hot, oil breaks down and gears wear faster. Worst case: thermal shutdown, production stops.

What ZLYJ does differently:

Real numbers:A Turkish PVC profile extruder runs 24/6 in a 42°C summer shop. After switching to ZLYJ with forced lubrication cooling system, oil temperature stays well below 90°C. Two years, no thermal issues.

Tell us your plant temperature and operating hours. We’ll verify thermal capacity before you order.

Q3: How long will the gearbox last? And how can I make it last even longer?

A:

Design life of main components: 25,000+ hours.

Thrust bearing life is easy to estimate with the formula:

Lh10 = (10⁶ / (60 × n₂)) × (Ca / Fa)^10

· n₂= output speed (rpm)

· Ca= bearing rated load

· Fa= your calculated axial thrust

Example from the field:

A Mexican automotive parts extruder had Fa = 165 kN, n₂ = 152 rpm. Using the formula, they got 33,800 hours of bearing life — nearly 4 years continuous running.

How to maximize lifespan:

A Thai recycling plant using a single-screw granulator ran their ZLYJ for 4 years with only annual oil changes. When they performed a scheduled inspection and opened the unit, gears and bearings showed minimal wear. They’re still running it today — now in year six.

We can calculate bearing life for your exact screw and speed. Send us your parameters and we’ll give you a number.

        📬shawn.zhu@helmedrive.com

ZLYJ Series Extruder Gearbox – Application-Based Selection Guide

◆When selecting an extruder gearbox for rubber and plastic machinery, it is essential to consider not only power and speed but also the unique demands of extrusion processes—high continuous torque, significant axial thrust from screw back pressure, and the need for exceptional reliability under continuous operation. Below is a practical selection guide based on real-world applications of the HelmeDrive ZLYJ Series Extruder Gearbox—built on real-world data, so you can choose with confidence.

◆The ZLYJ Series is a specialized gearbox designed specifically for single-screw extruders in the rubber, plastic, and chemical fiber industries. It features high-strength alloy steel gears with case-hardening and precision grinding (gear precision Grade 6 per GB10095, tooth surface hardness HRC 58–62), a dedicated thrust bearing assembly at the hollow output shaft to handle screw axial forces, and optional forced lubrication with cooling for continuous-duty reliability. The series is designed for input speeds up to 1500 r/min, operating in ambient temperatures from -40°C to 50°C, and can be used for both clockwise and counter-clockwise rotation (with special attention when a lubrication pump is fitted).

▼Product Overview

▼Application Areas

1. Plastic Extrusion Applications

Common Pain Points:

n High axial thrust from screw back pressure

n Continuous 24/7 operation requiring reliable cooling

n Need for precise speed control for consistent product quality

n Space constraints in extrusion lines

Selection Recommendations:

2. Rubber Extrusion Applications

Common Pain Points:

n Variable torque due to rubber compound properties

n Higher operating temperatures from rubber friction

n Need for robust sealing against carbon black and fillers

n Shock loads during start-up and material feeding

Selection Recommendations:

3. High-Power Continuous Extrusion Applications

Common Pain Points:

n High power requirements (up to 200 kW or more)

n Need for efficient cooling to maintain oil temperature ≤ 90°C

n Long service life requirements (10,000+ hours)

Selection Recommendations:

★Technical Specifications Reference

1. Recommended Configurations (Typical)

Note: Values are based on 4-pole motors (1500 r/min) unless specified otherwise (e.g., 6-pole motors for larger sizes).

2. Rated Power P_f and Output Torque T₂ (Table A-1)

Note: For complete rating tables, consult HelmeDrive engineering.

3. Gearbox Selection Example 

▸Input speed n₁ = 1500 r/min, required output speed n₂ = 152 r/min

▸Required ratio i_s = 1500 / 152 = 9.868 → select nominal ratio i_N = 10

▸Input power P = 45 kW → from Table A-1: ZLYJ200 has rated power P_f = 60 kW (60 ≥ 45, acceptable)

▸Thermal power check: P = 45 kW ≤ P_G2 (standard cooling coil) → acceptable

▸Axial thrust calculation (example):

▻Screw diameter d_s = 90 mm, screw pressure P_s = 26 MPa

▻F_a = π × (90² × 26) / (4 × 1000) = 165.4 kN

▸Thrust bearing life calculation (example):

▻Bearing rated load C_a = 923 kN, output speed n₂ = 152 r/min

▻L_h10 = (10⁶ / (60 × 152)) × (923 / 165.4)^10 ≈ 33,798 hours

★Understanding HelmeDrive ZLYJ Model Designation

Example: ZLYJ200-10-I

★What to Know Before You Buy

▹Calculate axial thrust accurately– Use the formula F_a = π × (d_s² × P_s) / (4 × 1000) to determine the thrust generated by the screw. Select a gearbox with sufficient thrust bearing capacity.

▹Select the correct size based on power– Refer to the rating tables to ensure P_f (rated power) ≥ P (required power). Account for service factors if the application involves shock loads or frequent starts.

▹Check thermal rating for continuous duty– For continuous operation, ensure P ≤ P_G2 with standard cooling coil. For high-power applications, forced lubrication with water cooling (inlet temperature ≤ 30°C) is recommended.

▹Consider rotation direction– ZLYJ gearboxes can run in both directions, but when a lubrication pump is fitted, the default rotation (facing output shaft) is clockwise. If counter-clockwise rotation is required, specify when ordering.

▹Lubrication is critical– Use CKD220 or CKD320 heavy-duty industrial gear oil. For forced lubrication systems, maintain oil pressure between 0.1–0.4 MPa and cooling water pressure between 0.2–0.3 MPa. The cooling water flow rate should be approximately 1.5 times the oil flow rate.

▹Ambient temperature matters– The gearbox operates in -40°C to 50°C. At low temperatures, preheat the lubricant or use low-temperature oil. At high ambient temperatures, ensure adequate cooling.

▹Mounting position– ZLYJ Series is designed for horizontal mounting. Consult HelmeDrive for other mounting orientations.

▹Let HelmeDrive help with selection– Proper sizing requires accurate load data, including screw diameter, maximum pressure, required output speed, and duty cycle. Send your application parameters to HelmeDrive for precise gearbox sizing.

By matching your selection to your actual working conditions and operational challenges, you ensure longer equipment life, lower maintenance costs, and higher product quality.HelmeDrive is committed to providing robust, efficient solutions tailored to your extrusion needs.

      📬shawn.zhu@helmedrive.com