“DRS 250 Wheel Block System solved frequent wear issues for cranes in Kazakhstan. ”
In recent years, driven by Kazakhstan’s "Nurly Zhol" (Bright Path) industrial modernization strategy, the nation has seen a surge in demand for high-performance material handling equipment. This is especially true in traditional industrial hubs such as Karaganda and Pavlodar, where sectors like heavy mining machinery, railway component manufacturing, and metallurgy demand exceptional reliability from overhead crane systems.
A leading heavy machinery parts manufacturer in Kazakhstan, specializing in core precision components for the Central Asian railway and energy industries, recently expanded its capacity. To ensure high-precision production, the company installed a fleet of Demag overhead cranes in its new modern workshop. However, during operation, the original wheel assemblies suffered frequent wear due to Kazakhstan’s unique environmental conditions and high-intensity production loads. This led to extended maintenance downtime and severely disrupted production schedules.
Core Challenges
Extreme Temperature and Environmental Demands Kazakhstan’s typical continental climate brings workshop temperatures exceeding 40°C in summer and extreme sub-zero temperatures in winter. These fluctuations challenge the stability of metal structures. Furthermore, high concentrations of metallic dust from metallurgical processing easily penetrate bearing interiors, leading to premature failure.
High-Intensity Continuous Operational Load To support the efficient operation of the China-Europe Railway Express and regional logistics, the plant operates on a 24/7 non-stop schedule. The cranes perform frequent heavy-load lifting with constant start-stop cycles, placing rigorous demands on the wear resistance and load-bearing limits of the wheel sets.
Maintenance and Logistics Cost Control Due to the geographical impact on spare parts supply cycles within Kazakhstan, the enterprise urgently needed a long-life wheel solution. The goal was a system that perfectly matches existing Demag equipment while significantly reducing failure rates and replacement frequency to optimize operating costs.
Technical Compatibility Requirements The replacement system had to be fully compatible with the existing Demag crane structures and rail parameters, ensuring a rapid return to production without the need for complex structural modifications.
The Solution: DRS 250 Wheel Block System
After a thorough technical evaluation, the manufacturer decided to upgrade the travel systems of all eight Demag cranes to the DRS 250 Wheel Block System.
Superior Structural Strength The DRS 250 features a high-grade spheroidal graphite cast iron housing, providing exceptional structural strength and impact resistance to withstand vibrations under heavy-duty cycles. The wheels are made of high-strength alloy steel with surface hardening, significantly enhancing wear resistance in harsh environments.
Advanced Sealing and Dust-Proof Technology To combat the severe metallic dust in the Kazakh industrial environment, the DRS 250 is equipped with high-precision, high-load deep groove ball bearings and a multi-layer sealing structure (including dust covers and seals). This effectively blocks external contaminants, preventing grease contamination and bearing seizure, ensuring stable long-term operation.
Seamless Compatibility with Demag Equipment The DRS 250 was engineered to align with Demag industrial standards. Its mounting dimensions and hole patterns precisely match the original models, enabling a "non-destructive installation." The maintenance team completed the upgrade in a short timeframe, minimizing production downtime.
Cost-Effective Operational Performance Compared to frequent purchases of expensive original spare parts or low-end alternatives, the DRS 250 offers a superior Return on Investment (ROI). Its low failure rate and extended service life significantly reduced the plant's long-term O&M (Operation and Maintenance) expenses, maintaining a cost advantage in the competitive Central Asian market.
Conclusion
The successful application of the DRS 250 Wheel Block System in this Kazakh factory demonstrates its reliability in extreme climates and high-dust environments. By precisely matching Demag crane parameters, the DRS 250 provides a robust and economical material handling solution for industrial upgrades in Central Asia. This case sets a technical benchmark for the promotion of the DRS series within the Eurasian Economic Union (EAEU) market. Want to reduce your long-term maintenance costs by over 30%, just like this leading Kazakh enterprise? Contact our [email]. Ensure high-efficiency handling with zero interruptions!
