Flender Gearbox Repair & Rebuild Services

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Why Choose Geartec for Your Flender Gearbox Rebuild & Repair?

Gearbox before repair
Gearbox after repair
Flender Graffenstaden has been a leading producer of high-precision turbo gearboxes for over a century. Flender manufactures industrial and maritime gearboxes for power generation and planetary gear units. At Geartec, we understand the importance of keeping your equipment up and running. We offer 24/7 emergency service to ensure our customers’ operation experiences minimal downtime. Whether you need a unit completely rebuilt or you need a new part, we have the equipment and experience to provide cost-effective solutions. Geartec is a well-known leader in the gear manufacturing industry, so we’re prepared to help with your industrial gearbox repair. Before we begin repairing your Flender gearbox, we conduct in-depth testing to understand which parts need replacing and what parts can be repaired. If the Flender gears are beyond repair, we can produce custom gears to fit your specifications. Our engineers have extensive experience in reverse engineering, gear manufacturing, and maintenance services that you can trust. Our manufacturing capabilities include Flender gears and shafts:
  • Helical
  • Double Helical
  • Herringbone
  • Spur Gears
  • Worm Gears
  • External Ring Gears
  • And More!
Quality is important to us. We strictly follow ISO standards to maintain unrivaled quality. We pride ourselves on our quick turnarounds, emergency breakdown repair, and personalized service 24/7. Don’t let your broken gearbox halt your operation, contact Geartec for Flender gearbox repair services!

Types of Flender Gearboxes

Flender Graffenstaden Gearboxes are known for extensive power applications and offer a multifaceted range of universal gear units, drive types, application-specific gear units, and customized solutions. Flender produces planetary gear units and wind turbine gearboxes; however, the most common types are bevel helical and helical gearboxes. At Geartec, our team of engineers puts a heavy focus on helical and bevel helical Flender gears and gearboxes.
  • Bevel Helical & Helical Gearboxes: One of the most popular types, Bevel Helical and Helical units are ultra-reliable and include a broad range of gear units. Applications include conveyor drives, agitator drives, hoist drives, dryer drives, and more.
If your Flender gearbox fails or breaks, it could result in costly downtime. At Geartec, we offer Flender gearbox repair, rebuild services, standard maintenance, and an in-depth analysis of industrial gearboxes. We serve a variety of markets and applications to keep their operation or plant running. We are always here to help! Our team works in continuous shifts to offer 24 Hour Emergency Service.

Cooling Tower Gearbox Maintenance You Can Trust

Custom gear CNC milling
Industrial in size and performance, Flender cooling tower gearboxes feature a unique design that’s engineered to handle extreme hot and cold temperatures quickly and almost simultaneously. They are often an important part of an operation’s total thermodynamic circle and must be maintained to Flender’s exacting standards with the right cooling tower gearbox parts; otherwise, the cooling tower fan can fail. At Geartec, we understand the unique mechanics of these industrial gearboxes and have the experience to service, repair, and rebuild the gears and drives on all Flender cooling tower gearboxes, even if your cooling tower features a custom-designed unit.

What Factors Can Lead to Cooling Tower Gearbox Failure?

Gearbox before repair
Gearbox after repair
When downtime is simply not acceptable, turn to Geartec for your Flender cooling tower repair needs. We offer decades of experience working on Flender equipment, and we’ve seen most of the major factors that can lead to gearbox equipment failure. Our knowledge helps us troubleshoot solutions quickly and helps you fix minor problems before they can hinder your entire operation:
  • High operating temperatures. Flender cooling towers are engineered to handle high operating temperatures, but this exposure can eventually lead to worn parts.
  • High humidity conditions. From ice to high-heat steam, gearboxes must be able to withstand water in all its forms and at its most extreme.
  • Wearing of gears. Over time, gears can experience wear due to many issues, including vibration. Let us help you inspect and repair gears before they need to be rebuilt.
  • Lack of maintenance. Because of the extreme conditions cooling tower gearboxes undergo, they must be cleaned and checked on a regular basis. If not, simple fixes can lead to larger repairs or necessary rebuilds.
  • Improper lubrication. We can not only fix issues caused by a lack of lubrication, but we can also help your maintenance team understand how to properly lubricate gears for better performance.
  • Environmental factors. Exposure to dust or other particulates can slowly wear down gears or drives. Proper maintenance can help offset this wear, but sometimes it can be unavoidable, especially if your facility experiences any type of extreme environmental event, including flooding, prolonged power loss, or other concern.

Our Cooling Tower Capabilities

At Geartec, we understand the need for cooling towers to keep temperature and humidity conditions under control. Gearboxes are paired with cooling tower motors to reduce fan speed and allow for a smaller, more cost-effective motor. Gearboxes in cooling towers act as a torque multiplier to take some stress off the motor.Because of large cooling tower applications, it’s imperative that maintenance and service issues are addressed regularly. Our team can help with routine inspection and gearbox repair. Cooling tower gear drives- Cooling towers require a functioning gearbox to reduce motor speed for an operation free of excessive sound and vibration. Premature gearbox failure can drastically impact your plant. Geartec has the expertise to replace any broken gear elements or completely rebuild your unit. Inspection and Maintenance- Being proactive and having your gearbox inspected and maintained regularly can significantly extend service life. Cooling tower gearboxes take on large loads at high-capacity production plants, so cooling tower service should not be overlooked.

We Service Gearboxes Across a Variety of Industries & Applications

Flender cooling tower gearboxes are used in some of the largest commercial and municipal applications that require process heat rejection. We offer experience working with a variety of high-use, high-stress conditions, including:
  • Biomass power plants
  • Oil & gas power plants
  • Waste incineration plants
  • Any field erected cooling towers or package-type cooling towers

FAQs

GearTec services and rebuilds a wide range of Flender gearboxes, including helical, double helical, bevel helical, herringbone, spur, worm, and external ring gear units. We specialize in Flender cooling tower, power generation, and industrial drive gearboxes, providing complete repair, rebuild, and testing capabilities to restore them to OEM or better performance standards.
Yes. If inspection and testing show that your Flender gears are beyond repair, GearTec can manufacture precision replacement gears that meet or exceed the original Flender specifications. Our in-house CNC machining and gear cutting capabilities allow us to produce custom components up to 96 inches in diameter and shafts up to 17 feet long, ensuring proper fit and performance.
A gearbox repair involves replacing or reconditioning specific worn components such as bearings, seals, or gears while maintaining the gearbox housing and main assembly.

A gearbox rebuild is a more extensive process where the unit is fully disassembled, inspected, and restored to like-new condition. Rebuilds typically include complete gear replacement, shaft reconditioning, bearing installation, precision alignment, and full testing before return to service.
Yes. GearTec offers 24-hour emergency service for Flender gearbox repair and rebuilds. We understand that unplanned downtime can be extremely costly, so our team operates in continuous shifts to respond quickly, perform on-site evaluations when needed, and minimize production interruptions.
Quality is at the core of everything we do. All gearbox repair and rebuild work follows strict ISO standards and is supported by in-depth inspections, failure analysis, precision machining, and controlled assembly. Before shipment, every gearbox undergoes testing and verification to ensure optimal performance, reliability, and alignment with Flender’s original design requirements.
Based on decades of experience, GearTec has identified several common factors that lead to Flender cooling tower gearbox failures:
  • High operating temperatures causing thermal fatigue
  • High humidity and water exposure leading to corrosion
  • Gear wear or misalignment due to vibration
  • Improper or insufficient lubrication
  • Lack of preventive maintenance
  • Environmental contamination such as dust, debris, or flooding
Routine inspections and proper maintenance can prevent most of these issues.
Yes. GearTec’s engineering team is highly experienced in reverse engineering and re-manufacturing older or custom Flender gearbox models, even if OEM drawings or parts are no longer available. We use advanced measuring technology and precision machining to recreate exact-fit components and restore the gearbox to full operation.
Inspection frequency depends on the operating environment, load, and temperature cycles, but generally, Flender cooling tower gearboxes should be inspected at least twice a year. GearTec offers preventive maintenance programs that include vibration analysis, oil sampling, and gear wear inspection to help extend gearbox life and prevent costly breakdowns.
Yes. In addition to in-house rebuild and machining capabilities, GearTec provides on-site inspection, removal, and evaluation for Flender gearboxes. Our technicians can assess gearbox condition, identify early signs of wear, and recommend repair or replacement before a full failure occurs.
GearTec supports a wide range of industries that rely on Flender gearboxes, including:
  • Power generation (biomass, gas, and waste incineration plants)
  • Oil and gas production and refining
  • Water treatment and cooling tower systems
  • Mining, pulp and paper, and general manufacturing
Our broad experience across sectors ensures we understand the specific operating demands of each application.
GearTec combines nearly four decades of manufacturing experience with state-of-the-art machining and testing capabilities. As a division of United Stars, Inc., we offer the resources of a global manufacturer while maintaining a responsive, customer-first approach. Our ability to manufacture new gears in-house, adhere to ISO quality standards, and provide 24/7 support sets us apart as a trusted partner for Flender gearbox repair and rebuilds.
You can contact GearTec directly through our website’s Request a Quote form or call our team anytime for emergency or scheduled service. A GearTec representative will review your gearbox specifications, condition, and requirements to provide a detailed estimate and turnaround plan tailored to your operation.

GearTec Makes Gearbox Repair Easy

Contact us today for a quick, no-obligation quote.

Contact Us or (440) 953-3900