Rotor repair & new build

All makes, from Lengerich, Germany

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Rotor repair

One of Germany’s largest rotor refurbishers

From 25-tonne shredder rotors to 500 kg hammer rotors: every year we repair over 100 different rotors for the recycling and natural stone industries, in our own workshop in Lengerich, Germany.

Over 40 years of experience and repairing ever more makes have shown us where rotors are weak and how to refurbish them for the long term. That know-how goes into every repair, from dismantling and measuring to final inspection by our quality assurance.

100+rotors repaired per year
500 kg – 25 thammer rotor to shredder rotor
40+years of experience
approx. 280rotor types for new builds

Repaired rotor with fitted pulley on trestles in the workshop

The rotor repair process

From dismantling to inspection report

01

Dismantling & measuring

All installed parts are dismantled and measured.

02

Refurbishment

Wear surfaces rebuilt, hardfacing matched to the application.

03

Balancing

Dynamically on our own rotor test stand, imbalance and smooth running checked.

04

Final inspection

Final test by quality assurance, inspection report included.

Rotor balancing

Dynamic balancing on our own rotor test stand

Before delivery, we test every rotor on our own rotor test stand for imbalance and smooth running and balance it dynamically with measuring instruments, whether it is a new build or a repair.

  • Bearings, shaft and all components checked
  • Final test by our quality assurance
  • Ready for use as soon as it is released

Rotor with detail view of the bearing point

Hardfacing of rotor bodies

Hardfacing for wear protection

The wire and welding process we use depend on your application and the condition of the rotor. We apply protective weld overlays to new builds and repairs in our workshop and, if the rotor is not too heavily worn, right in your machine. The rotor is then dynamically balanced.

  • Full or wear-zone hardfacing
  • Protective weld overlay on rotor discs
  • In our workshop or right in your machine
  • Less vibration, longer bearing life

Rotor with welded-on wear protection on trestles in the Prall-Tec workshop

Full hardfacing on a rotor
Full hardfacing
Wear-zone hardfacing on a rotor
Wear-zone hardfacing
Rotor discs on a rotor
Rotor discs

New rotors

Around 280 rotor types, built in Lengerich

New rotor with large pulley on wooden blocks in the Prall-Tec hall

If a repair is no longer worthwhile, we build your rotor new: for all makes, designed and manufactured in-house, even for rotor types that are no longer available.

  • Designed and built in Lengerich
  • For impact crushers of all makes
  • Long service life through special processes
  • Every rotor balanced before delivery

View all rotor types

Replica

To fit your impact crusher: built to the original, including rotor types that are no longer available.

Prall-Tec design

Reinforced retaining bar, special steel, refined welding and heat treatment for a much longer service life.

Replacement rotor

After severe damage from tramp material we build a cost-effective replacement, e.g. with special hardfacing or a front retaining bar instead of retaining pieces.

Custom solutions

Rotors with blow bars from other machines or built to your requirements, designed in-house.

Makes

Independent of the manufacturer, for these makes and many more

BöhringerMetsoPegsonHartlKeestrackKleemannHazemagSBM

More makes, hammer rotors too: Aebi · Altairac · Ammann · Arja · Aubema · Babbitless · Baioni · Baxter · BHS · Clasen · Comec · Dietlas · Dragon · Eagle · Elba · Esch · FAM · Galion · GFA · GHH · Gipo · Goodwin · Händle · Hazet · Hischmann · Hoger · Ibag · Jost · Keiser · Kemco · Kent-Maxecon · KHD · Klus Aebi · Kobelco · Kubus · Küken · Liebherr · Liedlbauer · Lindemann · Lokomo · Loesche · Loro & Parisini · Mannsberger · MEM · MFL · Miag · Mini · Minyu · Morgårdshammar · Neuman & Esser · Neyertec · Niederhageböck · Nordberg-Bergeaud · Nuova F. · O&K · OHL · OM · OMT · Parker · Pozzato · Ratzinger · Reiter & Crippa · Rheta · Rohr · Rotex · Rubble Master · Skoda-Prerov · Steimer · Symons · Teka · Tesab · Tipex · Universal · Via-Nova · Von Felten · Wedag · Weitz · Wibau

The brands mentioned are used for identification only and are the property of their respective owners.

References

A small insight into our rotor repairs

Refurbished rotor with bearing housing
Refurbished rotor
Detail view of a refurbished rotor
Detail after refurbishment
Newly built rotor with bearing housing on trestles in the Prall-Tec workshop
Newly built rotor

Is your rotor worn?

Tell us the make and rotor type. We’ll check whether a repair is worthwhile or a new build is the better choice.

Enquire about your rotor vertrieb@prall-tec.de +49 5481 402610-0

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