MAXXDRIVE Industrial Gear Units Enhance the Efficiency of Mixing and Agitation Systems

Heavy-duty MAXXDRIVE industrial gear units ensure mixing and agitating systems receive maximum operational reliability with a robust design to handle heavy loads.

MAXXDRIVE industrial gear units from NORD DRIVESYSTEMS are a proven solution for demanding, heavy-duty applications. Beyond their use in conveying, lifting, and driving functions, they are also essential in mixing and agitation processes. These gear units feature a compact, single-piece UNICASE housing, ensuring durability, low noise levels, minimal maintenance, and an extended service life. Engineered for strength, the design accommodates high axial and radial loads, delivers output torques up to 2,495,900 lb-in, and supports power outputs as high as 8,075 hp.

With advanced bearing and sealing technologies, MAXXDRIVE units offer enhanced reliability in operation. They include options such as extended bearing spacing for handling heavier loads, DRYWELL configurations for improved leak prevention using a built-in catchment flange and visual indicators, and TRUE DRYWELL designs for maximum safety, featuring reduced oil levels and standpipes.

Additionally, models with conical roller bearings are available for managing extreme axial forces. For real-time performance tracking, MAXXDRIVE agitator drives can be outfitted with sensors that monitor key operating parameters—including oil level, temperature, pressure, vibration, and potential leaks.

Drive Systems for Stack Mixers and Counter Rotating Drives

Coaxial drives are commonly used in stack mixers and counter-rotating systems that require dual agitators, particularly in large tank applications. These systems include agitator blades rotating in one direction at the tank’s center, while scraper blades move in the opposite direction along the tank walls. The scraper blades remove material adhering to the walls and reintroduce it into the mixing process.

NORD’s MAXXDRIVE solution utilizes a vertically stacked configuration with two MAXXDRIVE industrial gear units—one mounted above the other. This setup powers two concentric shafts: the inner shaft is driven by the top gear unit, operating the central agitator, while the outer shaft is powered by the larger lower gear unit, rotating the scraper blades. This design allows the two agitators to operate at different speeds and in opposite directions independently, enhancing mixing efficiency and flexibility.

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Drive Systems for Lauter Tuns

Lautering is a crucial step in the brewing process, acting like a large strainer to separate the wort from the solid components of the mash. The lauter tun drive is responsible for rotating and lifting the raking mechanism within the vessel, enabling the wort to pass through the grain bed for effective filtration. NORD offers highly customizable drive systems for lauter tuns ranging in size from 2 m³ to 30 m³, as well as standardized solutions for tanks with diameters up to 14 meters. These drives can be equipped with a spindle lift or configured to support hydraulic lifting systems, depending on the application’s requirements.

Drive Systems for Biogas

Effective mixing and agitation are critical processes in biogas plants. Proper blending of fermentation materials is essential to create a uniform mass, which in turn ensures optimal conditions for microbial activity—such as consistent temperature, viscosity, and pH levels. Active microbes are necessary for the efficient production of biogas.

When the Smits Group in the Netherlands expanded its large-scale agricultural biogas facility, it posed a unique challenge for the mixing technology designers. Unlike the conventional round tanks, this project required mixing over a rectangular base of approximately 1,200 m². Additionally, the tank structures featured more concrete pillars than usual, further complicating the installation.

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To address these challenges, Jongia Mixing Technology, a Dutch manufacturer, engineered a solution involving two high-performance agitators per tower to ensure efficient mixing and maximum biogas yield. Each agitator, equipped with a 4.5-meter shaft, is powered by a MAXXDRIVE industrial gear unit. In total, 16 ATEX-certified NORD gear units were used, each driven by a 50 hp motor and achieving a 123:1 reduction ratio, resulting in nearly 257,000 lb-in of torque. Plans are already underway for the construction of another biogas plant featuring eight fermenters equipped with MAXXDRIVE gear units to further boost biogas output.

For more details on MAXXDRIVE industrial gear units, visit www.nord.com.