How Tyrolit increased profitability by 32%

Case study

Increasing efficiency in the machining of large gears

In today’s metalworking industry, companies face enormous challenges. The constant need to reduce production costs while simultaneously shortening process times and maintaining or even improving product quality puts many companies under pressure. Inefficiencies in grinding and cutting processes often lead to unnecessary costs and extended production times—both of which can significantly impact profitability.

Our customer, a leading manufacturer of gearbox components for the wind power industry, was facing these exact challenges. Before partnering with Tyrolit, the company struggled with inefficient grinding processes that were not only costly but also time-consuming. As a result, benchmark trials were conducted with several suppliers, of which only two met the required quality standards.

This whitepaper presents a real-world example of how Tyrolit helped a customer in the wind power industry increase the profitability of their grinding processes by 32%—all while maintaining consistently high quality.

Overview of Challenges in Metalworking

Increasing price pressure

Globalization has intensified competition, especially with the entry of lower-cost suppliers from countries like China. Companies must continuously reduce their production costs to remain competitive while still meeting high-quality standards.

Long process times

Inefficient processes, particularly in grinding and cutting technology, can lead to significant delays in production. This is especially critical in industries like wind power, where high volumes and precise machining are required.

High production costs

In addition to price pressure, inefficient production processes significantly contribute to overall costs. Every additional step and every inefficient tool increases the cost per unit produced, thereby reducing margins.

Tooling industry STARTEC XPC flute grinding

Quality assurance

Ensuring consistently high product quality while simultaneously reducing costs is another major challenge. Grinding tools must be durable, precise, and reliable to meet the stringent requirements of the final products.

Environmental and safety requirements

Stricter environmental regulations and safety standards require companies to operate not only efficiently but also sustainably and safely. This is particularly relevant when handling grinding tools and using machines that consume less energy and produce less waste.

Tyrolit’s approach: Precision grinding at the highest level

With over 100 years of experience and as a global leader in precision grinding technology, Tyrolit understands these challenges well. Our mission is to provide customized solutions that not only increase profitability and efficiency but also secure the competitiveness of our customers. With more than 35,000 industrial customers worldwide and a wide range of innovative products, we are setting new standards in metalworking.

Case Study

1. Analysis and consultation:

Tyrolit began the project with a comprehensive analysis of the customer’s existing grinding processes. Our specialized application engineers for large gear grinding visited the customer on-site to conduct a detailed assessment of the processes, workpieces, materials, and machines. The goal was to increase the profitability of the processes and reduce production costs through targeted measures.

2. Tool optimization with ALPHA TECHNOLOGY:

By introducing Tyrolit’s ALPHA TECHNOLOGY, a specially developed high-performance grinding grain, we were able to significantly extend tool life and increase production speed by reducing tool changes. This led to a 27% improvement in the G-ratio, indicating a more efficient grinding process with a better ratio of material removal from the workpiece to the wear on the grinding tools.
This optimization directly contributes to reducing production costs as the tools can be used longer and production times are shortened.

3. Process optimization:

In addition to tool optimization, Tyrolit reviewed and optimized the entire grinding process. By adjusting grinding and feed speeds as well as depth of cut, we were able to maximize material removal without compromising surface quality. Notably, the feed rate was increased by 43% in roughing and 11% in finishing, leading to a significant reduction in processing times. These measures enabled the customer to significantly increase the efficiency of their production processes.

4. Burn-free high-performance grinding:

In the hard-fine machining of large gears, burn-free grinding results are of the utmost importance. At the same time, processing costs need to be optimized. Thanks to our optimizations, the customer was able to maintain consistent profile retention of the grinding wheel despite higher process parameters, further reducing production costs.

Results and success story

50% MIRA ALPHA mix vs. 100% triangular grain

Achieved the same grinding result with 20% lower costs.

Reduction in processing time

Q’w increased from 9 to 16, V’w increased from 1500 to 4000.

Increased profitability

Overall processing time was significantly reduced while maintaining process stability, resulting in a 32% increase in efficiency.

Cost reduction

Significantly faster process times led to a substantial reduction in production costs.

These optimizations enabled the customer to cope with price pressures while exceeding production goals. Tyrolit established itself as the preferred partner with the best price-performance ratio.

Key stakeholders from the wind power industry

"In terms of price/performance, Tyrolit has the best solution."

Why Tyrolit?

1. High-precision grinding technology:

Tyrolit develops innovative grinding solutions tailored to the demands of challenging industries. Our technology enables workpieces to be machined with the highest precision, resulting in consistent surface quality and extended tool life. This is especially important where accuracy and efficiency are top priorities.

2. Process optimization and cost reduction:

By optimizing grinding processes, including selecting the optimal grinding tool and fine-tuning machine parameters, production times can be shortened, and production costs reduced. Tyrolit works closely with its customers to develop customized solutions that not only improve the quality of the machined workpieces but also increase the efficiency of production processes.

3. Sustainable production and resource conservation:

Another highlight of Tyrolit products is their contribution to sustainable production. The longer tool life and reduction of waste materials contribute to resource-efficient manufacturing. This is not only environmentally friendly but also reduces operating costs in the long term.

Tyrolit's contribution to sustainability and innovation

Tyrolit is committed to sustainable development and continuous innovation. The company is dedicated to developing products and technologies that not only enhance performance but also protect the environment. This is evident in the development of grinding tools with longer lifespans that need to be replaced less frequently and the reduction of waste through optimized production processes.

Moreover, Tyrolit continuously invests in research and development to ensure that its products are always at the cutting edge of technology. The company works closely with leading research institutes and universities to develop innovative solutions that meet the growing demands of the industry.

Conclusion

Rising production costs and inefficient grinding processes burden companies in metalworking.

Tyrolit offers you the opportunity to make your grinding and cutting processes more efficient and increase your profitability. Our advanced grinding technologies and customized solutions provide longer tool life, shorter processing times, and less wear—all while maintaining consistently high quality.

Contact Us

Contact us today to schedule a non-binding consultation:

Jörg Pfister
Head of Solutions Management Metal Industries

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