Lucky Cement gears up for the future

Lucky Cement Ltd encountered a problem with one of the bearings of the WPU 200 G gear of the vertical mill at its Karachi plant in Pakistan. While the vertical mill gear WPU 200 G is well-known for its robustness and efficiency in demanding industrial applications, even the most durable equipment requires periodic maintenance and upgrades to perform optimally.

Need for overhaul

The need for the overhaul was identified during a regular inspection, which highlighted a developing issue with bearing No 1. This observation prompted an in-depth discussion between MAAG and Lucky Cement’s maintenance team. Both parties agreed that it was prudent to not only replace the faulty bearing but to replace all bearings in the gearbox. By taking this preventive action, Lucky Cement aimed to avoid future breakdowns, minimise downtime and optimise the operational efficiency of the gearbox.

The WPU 200 G gearbox had been in service for many years and while it had performed reliably, the natural wear and tear of components such as bearings made it necessary to replace them to maintain the high standards of performance expected by the customer. The decision to replace the bearings was seen as an investment in the future reliability of the equipment.

High level of preparation results in rapid project completion The overhaul of the gearbox was conducted on site. Typically, MAAG estimates that a gearbox overhaul of this magnitude would take approximately

three weeks. However, thanks to the long-standing relationship between MAAG Gear and Lucky Cement, the project was completed faster than expected. One of the key reasons for the speedy completion was the high level of preparation by both teams.

Lucky Cement had booked the necessary crane and secured all required tools well in advance of the overhaul. This ensured that no time was lost waiting for equipment or personnel to arrive. In addition, the skilled manpower from Lucky Cement was on-site and ready to assist the MAAG team. The mutual understanding between the two companies, built over years of collaboration, meant that both parties knew exactly what was required for the project to be completed efficiently and effectively.

The fast-tracked completion of the project showcased MAAG’s ability to deliver not just high-quality gearboxes but also swift and professional on-site service. By minimising downtime, MAAG helped Lucky Cement avoid costly production delays, further cementing the value of their partnership. “Close cooperation with the skilled team assigned by Lucky Cement was the key success factor,” said Szymon Sawicki, field service engineer delegated by MAAG Gear to Pakistan to supervise the gearbox overhaul.

Specialist supervision

MAAG Gear deployed a single supervisor for this project, demonstrating confidence in both the customer’s team and the streamlined process. “Deep understanding of our gearbox and experience with similar projects can significantly increase probability that such project will be successful” said Michal Zaskiewicz, head of MAAG’s customer service department. Trust and respect between MAAG and Lucky Cement were paramount in ensuring the success of the project. By working together as a cohesive unit, the two teams were able to complete the overhaul in record time, without sacrificing quality or attention to detail.

Positive feedback Following the successful completion of the overhaul, Lucky Cement expressed its satisfaction with MAAG’s service. The positive feedback centred on the efficiency of the process: “We are pleased to express our gratitude to MAAG Gear for the exceptional overhaul of the WPU 200 gearbox for the vertical roller mill, completed in record time and to our utmost satisfaction,” said Aslam Baloch, director of operations at Lucky Cement.

“MAAG Gear products continue to reflect the exceptional quality and reliability that we have come to trust. The entire overhaul process went smoothly, and the quality of the work met the highest standards we expected from MAAG Gear products and MAAG Gear service,” he added.

Conclusion

The overhaul of the WPU 200 G gearbox at Lucky Cement’s Karachi plant exemplified MAAG Gear’s commitment to providing fast, efficient, and high- quality on-site services. By working closely with the customer and leveraging years of experience, the company was able to complete the project faster than anticipated, while still delivering exceptional results. The positive feedback from Lucky Cement underscores MAAG’s position as a leader in the gearbox industry.

MAAG is committed to providing every customer with professional overhaul services and top-quality spare parts, ensuring the highest productivity for critical plant equipment. Its dedicated team stands ready to deliver reliable, high- performance solutions tailored to meet the unique demands of each operation.

This article was published on International Cement Review 10.01.2025