South Africa Reverse Engineer a Sugar Mill Gearbox Using 3D Scanning Technology
In May 2024, during a routine inspection at a sugar mill in Mauritius, David Brown Santasalo’s (DBS) engineering team in South Africa identified significant wear on a critical gearbox component - a pinion gear responsible for driving our customer’s mill. Recognising the urgency and complexity of the issue, we proposed a reverse engineering solution using our advanced 3D scanning technology to manufacture a precise replacement.
The gearbox, weighing approximately 4.5 tonnes and measuring 2.5 metres in length, was a substantial unit. Despite the severe wear on the original component, our team confidently deployed our new 3D scanners to capture accurate geometries and dimensions. This allowed us to produce a high-quality replacement pinion, tailored to the exact specifications required for the gearbox to return to full operation.
The project was led by our Senior Engineer Robert Jacobs, who coordinated closely with internal departments. Robert also consulted with our Development Director Mike Field, who has been with the David Brown Santasalo business for over 45 years, to ensure the highest standards were met throughout the process. The result was a seamless collaboration that showcased the strength of our in-house expertise and commitment to quality.
There is always increased pressure on engineers when they have only a single opportunity to take measurements, or capture data required for the manufacture of new drop-in replacement parts. As the Field Service Manager, I am proud of the exceptional collaboration demonstrated by the team in successfully executing a complex task in a remote location, from initial drawings through to manufacturing and final installation.
The Project Timeline
- Inspection & Recommendation: May 2024
- 3D Scanning: September 2024
- Manufacturing: December 2024
- Shipping to Site: February 2025
- Installation & Commissioning: May 2025
Our customer, a key player in the African sugar industry, was extremely satisfied with the outcome. Not only was the gearbox successfully restored to full operation, but the client also praised the quality of the replacement gear and the professionalism of our site team during installation and commissioning.
This project highlights DBS’s growing capabilities in reverse engineering and the value of integrating 3D scanning into our workflow. The utilisation of advanced 3D scanning technology to replace the rotating components ensures minimal downtime during the reverse engineering process, and can be executed at any location, effectively eliminating all potential obstacles for the customer.
By combining precision technology with expert craftsmanship, David Brown Santasalo continue to deliver reliable, efficient solutions for heavy industrial applications. Contact your local DBS team to find out how we could transform your next emergency shutdown, www.dbsantasalo.com/contact.