Pinion teeth build up

Sugar • Deoband,Uttar Pradesh , IN

APPLICATION (+1 pts)
APPROVED

Basic Information

Overview

Pinion Dimensions & Inspection: - ID: 420 mm - OD: 480 mm - Teeth Dimensions: Height 65 mm x Width 63 mm

Industry

Sugar

Location

Deoband,Uttar Pradesh , IN

Component/Workpiece

Pinion teeth build up

Business Type

Consumable Sales

Job Type

Repair

OEM

Shanti Gear

Type of Wear

Impact
Shock load

Tags

welding processes
gear pinion teeth
build-up welding
build up

Base Metal

Forged Alloys Steel

General Dimensions (mm)

- ID: 420 mm - OD: 480 mm - Teeth Dimensions: 65 mm (H) x 63 mm (W)

Problem Description

The challenge the customer was facing

Required Gear Pinion Teeth Build-Up Jobs** The objective of this project is to execute gear pinion teeth build-up jobs that ensure cost-effectiveness while providing high-quality service and extended operational lifespan.

Previous Service Life

16w

Competitor

EWAC

Welding Alloys Solution

How WA solved the challenge

WA GAMMA 182 E (4x350 mm)

Product Category

Consumables

WA Product Used

GAMMA 182 E

Diameter

4.0 mm

Job Duration

1d

Technical Advantages

WA Solution & Process: - Grinding Surface area and pre heat - Consumable: WA GAMMA 182 E (4x350 mm) - Process: Built-up using the specified WA GAMMA 182 E electrodes. - Again Grinding for finishing. - Stress Realise Quality Control: - A Dye Penetrant Test (DPT) is to be conducted after the built-up process is complete.

Service Life

16w

Images (7)

Photos and visuals for this case study

Case study image 1Case study image 2Case study image 3Case study image 4Case study image 5Case study image 6Case study image 7

Supporting Documents (1)

Documents and files for this case study

doc_1777182852699_T.SUGAR_MOM___2_.pdf

Click to view or download

Financial Impact

Solution Revenue

€517.26

Cost Reduction Analysis

Annual Cost Before

€1,088.96

Annual Cost After

€517.56

Annual Savings

€571.40

52.0% reduction

Annual Cost Comparison
Previous Solution€1,088.96
WA Solution€517.56

Cost Breakdown

Part Information
Cost of Part (A):€1,088.96
Cost of WA Solution (B):€517.56
Parts Used/Year (E):1
Solution Lifetime Comparison
Previous Solution:3.7 months
WA Solution:3.7 months
Before (Previous Solution)
Maintenance/Repair (F):-
Disassembly Cost (G):-
Downtime/Event (H):-
After (WA Solution)
Maintenance/Repair (F):-
Disassembly Cost (G):-
Downtime/Event (H):-
Formula Used

Annual Cost = (A × E) + (E − 1) × (F + G + H)

Where: A = Cost of Part, E = Parts/Year, F = Maintenance, G = Disassembly, H = Downtime

Additional Benefits

1 .Competitive cost-effectiveness 2. Site work requirements 3. Timely delivery 4. Customer trust and satisfaction

Submission Details

Contributor

Gautam Dhanwantry

gautam.dhanwantry@welding-alloys.com

Created

April 26, 2026

Submitted

April 30, 2026

Approved By

Bastien Gerard

May 3, 2026