Dual‑Speed Precision, Delivered by DBS India
DBS India has successfully completed the design and manufacture of a Main Drive Dual-Speed Pinion Stand Gearbox for a leading aluminium producer in India. Our customer’s plant, with an annual smelting capacity of 20,000 tonnes, operates across smelting, rolling, and extrusion processes, critical to India’s industrial growth.
To ensure uninterrupted operations, the customer commissioned a new Pinion Stand gearbox to replace their existing unit after 22 years of service. The new gearbox is a two-stage, double-output main drive unit with dual-speed capability, weighing an impressive 21,000kg and powered by two 1200 kW motors connected in series.
The complete manufacturing process, from casing fabrication and precision machining to gear production, assembly, and no-load trial testing, was completed within the desired six-month lead time. One of the key challenges was the grinding of a 3280mm double-helical pinion shaft gear, which we successfully executed in-house using DBS India’s advanced Gleason P1200G machine.
The gearbox is equipped with specialised accessories, including a pneumatic actuator and clutch system, which enable speed changes during operation. All internal components of the gear‑shifting assembly are manufactured in‑house and precision shrink‑fitted to ensure smooth, reliable engagement.
During a visit to our Hosur facility, the customer observed the no-load test and was pleased to see the gearbox deliver seamless dual-speed operation, consistent oil flow, precise spray nozzle performance, and maintain optimal temperature and vibration levels throughout.
"Delivering this gearbox was a great example of our team’s engineering capability and commitment to quality. From precision machining to the complex double helical pinion shaft grinding, every stage was completed inhouse to ensure the highest standards. It was rewarding to see the unit perform exactly as designed during no load testing, and we’re proud to support our customer with a reliable, long term solution."
This project highlights our engineering expertise, commitment to quality, and ability to deliver complex solutions on time. Commissioning is planned for early 2026, and we’re proud to play a role in supporting India’s aluminum industry.