Complete Rebuild of a Gear Reducer for Marine Pump

A major South American company, active in the offshore crustacean processing sector, contacted us to solve a critical issue: a gear reducer installed on a shrimp processing pump was deteriorating to the point that traditional repair was no longer possible.

The request was clear: completely rebuild the reducer, adapting it to the extreme conditions of use on board a floating marine processing unit.

A complex project, with specific requirements for resistance, adaptability, and durability.

The challenge: a harsh environment and demanding requirements

The operating conditions were among the most difficult:

• Constant exposure to salt water and high humidity;
• Irregular but intense loads, typical of pumps used to handle crustaceans;
• Constrained construction layout, with limited space available;
• Requirement for maximum reliability and zero unplanned interventions.

The Riduttori Italia solution: a brand-new, custom-made reducer

Our technical team carried out a detailed analysis of the old reducer, reconstructing its geometry, mechanical features, and operating conditions.

We then designed a completely new reducer with the following features:

• Anti-corrosion structure: housing made of treated alloy with high-performance protective coating, suitable for marine environments.
• Enhanced sealing system to prevent saltwater infiltration.
• Optimized transmission ratio to maintain a constant pump flow rate.
• Improved internal lubrication, using synthetic oils specific for marine applications.
• Customized flanging for direct coupling with the existing pump.

All machining and assembly operations were carried out in-house, including dynamic testing and performance validation.

The results: a second life for the system

After delivery and on-board installation, the new reducer resumed full operation. Over 12 months into service:

• The system has achieved zero downtime.
• Pump performance is stable, with reduced wear.

The customer avoided full system replacement, optimizing costs and extending the equipment’s operational life.

What we can do for your company

At Riduttori Italia, we specialize in revamping and complete reconstruction of gear reducers. If you have a damaged, obsolete, or discontinued component, we can reproduce it, enhance it, and make it more efficient—even in demanding environments such as offshore installations.

We work with clients all over the world, ensuring:

• In-depth technical analysis
• Customized mechanical design
• Reliability, durability, and ongoing technical support

Do you need to replace or rebuild a discontinued gear reducer?
Contact us: we’ll find the right solution for your system.