Flender one: Next Chapter Flender Expands its Game-Changing Gearbox Lineup with Flender One

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“We are reinventing the standard,” declared CEO Andreas Evertz when Flender introduced the Flender One single-stage version to the market last year. Now, this reinvention enters its next phase. Flender announces the global launch of the latest extension of Flender One gearboxes. Building on the success of models designed for pumps and paper applications. Flender One is now set to offer versatile solutions for over one hundred different applications, broadening its market reach and impact.

The new gear units are designed to meet a wide range of application needs,including bucket elevators, belt conveyors, and hoisting applications. With a broadspectrum of power classes, sizes, and designs, these gear units ensure optimalcoverage of various industrial requirements.

Perfect fit with each gearbox

Flender One stands out with its tailored solutions. Customers only purchase whatthey need, eliminating unnecessary components and maximizing efficiency. According to the developers from Flender this customization reduces operating expenses and enhances performance, providing aperfect fit for each specific application. Additionally, the gearboxes offer a widerange of add-on parts and customizable output shafts. The Flender One design saves both time and money in planning and plantoperations. 

The new configuration process can be completed in minutes with justthree parameters. Combined with instantly accessible 3-D data, prompt quotations,and shorter delivery times due to automated manufacturing processes, project timelines are accelerated from the planning phase. Overall, plant operators canachieve up to 25 percent time savings in planning through simplified processes.In operation, the Flender One platform reduces operating expenses. 

All gearboxesare equipped with performance-optimized Metaperform gearing, reducing powerdissipation by up to 20 percent compared to previous models and a 30 percent higher thermal capacity. Also, the bearing lifetime increases by 80 percent. This results in faster cost amortization for industrial gearboxes from Flender than everbefore.

Smart gearboxes with AIQ technology

Flender One offers built-in gear unit intelligence straight from the factory. Each unitcomes with an integrated AIQ Core sensor, providing digital monitoring and intelligent onboard analytical functions. This allows for increased plant availabilityand process optimization, reducing unplanned downtime by up to 70 percent. Data-and need-based maintenance intervals can decrease service costs by up to 40percent and service-related downtime by up to 50 percent. The optional torque measurement function allows for process and operating point optimization. The AIQCore torque can be easily selected via the configurator.

Rouven Daniel, President Industrial Gear Units at Flender, also once again stressesthe fact that with the help of collected data and AI models, Flender is now able tosize the gearboxes only as large as needed for the respective application. “Mostindustrial gearboxes from all manufacturers in the field, including Flender, areoversized by up to 50 percent. With Flender One and AIQ, we have the right tools tocontinuously eliminate this oversizing together with our customers. As a result, wewill realize massive savings in raw materials, energy consumption, delivery timesand installation space. Any waste is eliminated in terms of the environment andcosts.”

On the way to the customized gearbox

In the future, further expansions of the Flender One platform will make it possible toconfigure gearboxes tailored to the respective application and the associatedrequirements. Despite maximum individuality, customers will benefit from theadvantages of series production: Process efficiency in production and thus fastdelivery times and low costs. This is made possible by a real milestone in transmission manufacturing: thecomplete digitization of the engineering process. It triggers the design exactly according to customer requirements and translates it into a fully automatedmanufacturing and delivery process.

Flender CEO Andreas Evertz states, "Flender One represents a significant shift inhow we think about gearboxes. It is not just a mechanical iteration of its predecessor FSG but an entirely new solution from the first customer inquiry to operation in theplant.”

Rouven Daniel adds, "Flender One stands for being more individual, efficient, and smarter. With an easy-to-understand configuration process, automated manufacturing, and comprehensive 3-D data and documentation in the cloud, itsaves our customers valuable time. In operation, Flender One excels with improved power dissipation and AIQ optimization, making it the most efficient Flender gearbox solution we have ever introduced."

A Proven Successor

Flender One succeeds the renowned standard industrial gearbox range, FSG, with over 500,000 units in the field. As the most successful standard industrial gearbox range to date, FSG sets a high bar, but Flender One is ready to surpass it with its innovative features and superior performance.