Gear Forgings Supplier

In the high-intensity world of food and feed manufacturing, the efficiency of a pellet mill or a mixer is entirely dependent on its transmission accuracy. These machines operate under high-frequency load cycles where even the slightest mechanical slip or surface degradation can compromise raw material processing and lead to batch non-compliance. To ensure stable, high-torque performance while meeting rigorous hygiene standards, the industry relies on gear-ring forgings as the gold standard for power transmission.

At ACE Group, we leverage our integrated "Forging-Machining-Polishing" layout to produce transmission components that balance heavy-duty strength with sanitary excellence. Utilizing our specialized vertical ring rolling machines at Jiangsu ACE Energy Technology, we deliver forged rings that define reliability in modern food and feed machinery.

1. Structural Integrity: The Advantage of Seamless Ring Rolling

A transmission ring is only as strong as its weakest point. Unlike "welded-plate" rings or "cast" rings, ACE Group gear-ring forgings are produced through seamless ring rolling. This process expands the metal diameter while compressing the grain structure into a continuous, circular flow.

Why Seamless Forging is Essential:

• Uniform Load Distribution: The continuous grain flow ensures that transmission forces are distributed evenly across every tooth, preventing localized fatigue.

• Superior Wear Resistance: Forging eliminates internal porosity, ensuring that once the teeth are machined, the metal remains dense and resistant to the abrasive nature of raw feed materials.

• Dynamic Stability: Our seamless rings maintain perfect circularity under thermal expansion, reducing vibration and noise during high-speed mixing.

2. Sanitary Excellence: Ra ≤ 0.8 μm Polishing

In food-grade applications, the surface finish is a safety requirement. After the precision machining phase at Yancheng ACE Machinery, our gear-ring forgings undergo a specialized sanitary polishing process.

• Surface Finish: We achieve a roughness of Ra ≤ 0.8 μm, creating a "mirror-like" finish.

• Safety Benefit: This ultra-smooth surface prevents the adhesion of organic materials and additives, making the gears easy to clean and preventing the microbial growth that leads to contamination.

• Compliance: Our production meets international food safety standards, supported by our TÜV Rheinland ISO 9001 certification.

3. Integrated Protection: The 400μm Weather-Resistant Shield

While the gear teeth are polished for sanitary use, the external housing and structural connectors require a different kind of protection. Yancheng ACE Surface Treatment Technology provides a heavy-duty powder coating with a one-time thickness of 400μm. This ensures that the non-contact areas of the machinery are fully protected against the humid and corrosive environments typical of feed processing plants.

4. Technical Specifications & Material Compliance

5. Frequently Asked Questions (FAQ)

Q1: Why is stainless steel forging preferred over carbon steel for feed gear-rings?

A: Feed raw materials often contain moisture and acidic additives that quickly corrode carbon steel. By using compliant stainless steels (304, 316L) in our gear-ring forgings, we ensure the components resist erosion and prevent rust from contaminating the feed.

Q2: How does the "Ra ≤ 0.8 μm" finish impact the longevity of the machine?

A: Beyond hygiene, a smoother surface reduces friction during the tooth-meshing process. This leads to lower heat generation and less mechanical wear, directly reducing downtime and extending the maintenance intervals for your equipment.

Q3: Can ACE Group handle custom gear-ring designs for non-standard machine models?

A: Yes. Our Jiangsu facility is equipped with 1-meter and 1.5-meter vertical ring rolling machines. We specialize in customized production, allowing us to adapt to specific machine geometries while maintaining the high-strength properties of a forged ring.

Q4: How do you verify the quality of the gear teeth after forging?

A: We implement strict Non-Destructive Testing (NDT), including ultrasonic and magnetic particle testing, followed by precise dimensional inspection in our machining workshop to ensure every gear tooth meets the exact profile required for efficient transmission.