Tag Archives: gearbox

Garlock Launches FLOOD-GARD Bearing Isolators for Fully Flooded Applications

FLOOD-GARD Offers Bearing Protection in Challenging Flooded Environments

Garlock has launched FLOOD-GARD Bearing Isolators for flooded applications. The patent-pending seal design provides bearing protection even in the most challenging flooded environments, extending the life of rotating equipment such as gearboxes, pumps, and motors.

“FLOOD-GARD™ allows Garlock to unlock value for our customers by taking industry leading bearing isolator technology, and advancing it even further, into a seal that excels in flooded conditions,” says Kevin Allison, Product Manager, KLOZURE®.

The latest addition to Garlock’s family of KLOZURE® Bearing Isolators, FLOOD-GARD™ is a revolutionary seal that combines improved safety and overall process efficiency with cost savings through extended equipment and bearing life. FLOOD-GARD’s Cam-Lock design provides excellent bore retention while allowing easy installation by hand, without the need for an arbor press. Other benefits include the ability to accommodate up to .015” of radial shaft misalignment and patented PTFE unitized construction that eliminates metal-to-metal contact, all while achieving an IP66 rating in most configurations — flanged, small cross section, step shaft and vertical.

FLOOD-GARD Benefits

  • Patented seal design provides bearing protection even in the most challenging flooded environments, extending the life of rotating equipment
  • Rugged, unitized construction for ease of installation
  • IP66 in most common design configurations
  • Available in standard and small cross section configurations
  • Substantially reduced installation time – NO ARBOR PRESS NEEDED
  • No metal-to-metal contact between stator and rotor
  • Handles up to .015″ of misalignment

FLOOD-GARD™ allows Garlock to unlock value for our customers by taking industry leading bearing isolator technology, and advancing it even further, into a seal that excels in flooded conditions.

FLOOD-GARD Design Parameters

  • Temperature: -22ºF (-30ºC) to 400ºF (204ºC)
  • Shaft to bore misalignment: ±0.015” (0.38 mm)
  • Axial motion to ±0.010” (0.25 mm)
  • Surface speed: to 3,000 FPM Max. (15.24 m/s)
  • Pressure: 7 psi intenal pressure

FLOOD-GARD Beta Sites

  • Gearboxes are common, but industries vary
  • Over 100,000 hours of runtime
  • Great success in all these industries

Beta Sites


For more information about Garlock products, or to learn more about the FLOOD-GARD, contact Gallagher Fluid Seals today.

Gallagher Fluid Seals is a preferred distributor of Garlock products and can help provide custom engineering solutions.

A History Lesson of the Falk Gearbox – How are they Related to Beer?

Falk Gearbox

It’s no secret that Falk gearbox parts have powered some of the world’s largest machinery for more than a century. But what most folks don’t realize is that the manufacturer’s legacy was built upon a river of beer.

That’s right. Before the Falk picture of Falk Gearbox family made its name in the power transmission industry, German immigrant Franz Falk co-founded the fourth-largest brewery in Milwaukee, Wisconsin. His success as a brewer helped establish the city as the “beer capital of the world”—and gave his son the wealth he needed to build what would one day become a leading gear manufacturing company.

From Wisconsin beer to Oregon gearboxes, products bearing the Falk name tend to rise to the top. So it’s no surprise that Franz’s Bavaria Brewery, founded in 1856, was a hit despite the stiff competition. With a 200,000-barrel production capacity (rivaling even some of today’s major breweries), the Falk family brewery outpaced both Schlitz and Miller combined during its peak years.

When a Fourth of July fire destroyed part of the brewery in 1889, so much beer spewed out into the Menomonee Valley you could stand in it up to your ankles.

Franz had passed away by that time, pabst blue ribbonbut his sons rebuilt and kept on making his popular beer. When fire struck again, however, they decided not to rebuild. They sold, instead—to Captain Frederick Pabst for $500,000 worth of stock in his own brewery. The Falk family made the Pabst Brewery Company the largest brewery in the entire United States. Pabst Blue Ribbon made the Falk brothers rich.

From Beers to Falk Gears

Herman Falk, the fifth of Franz’s seven sons, wasn’t a big fan of brewing. He was more mechanically inclined.

An inventor and entrepreneur, he acquired his first patent at the age of 20, for “new and useful improvements in wagon-breaks.” By 1892, he had started a business making couplings for wagons. Today, Falk gear couplings are considered the industry gold standard. Back then, however, wagon couplings weren’t enough to sustain a business.

Fortunately, the money from the sale of the family brewery allowed him to expand. He soon opened a general-purpose machine shop in an old blacksmith building, where he built stage machinery for the Pabst Theater when he wasn’t working on wagons. Before long, a new technology caught his attention: electrified transportation. He invented a breakthrough process for manufacturing the joints between streetcar rails, and by 1900 nearly a third of the nation’s rail street rail tracks had Falk castings.

By that time, Falk had moved on to power transmission. As factories transitioned from steam power to electric motors, gears were needed to convert their superfluous speed into torque for driving conveyor belts and machine tools. Falk’s newly built 70,000-square-foot factory began pumping out gears and pinions in response.

But Falk wasn’t satisfied with producing ordinary spur gears for streetcars. He had heard of a Swiss machine that could produce precision herringbone gears. He bought the U.S. rights and debuted his new gears in 1911.

“Herman’s decision to enter the precision gearing field was undoubtedly the pivotal event in the company’s history,” says Milwaukee historian John Gurda.

Gearing Up for Success

It wasn’t long before Falk was producing heavy industrial gears for oceangoing vessels—including U.S. naval ships. He even made the gears that open and close the giant mechanical gates of the 51-mile-long Panama Canal, according to the Milwaukee County Historical Society.

The company has since manufactured more than 1,200 reverse reduction drives for tugboats and towboats as well as more than 1,800 special reduction gears for cruise ships, aircraft carriers and other marine vessels.

Today, Falk gearbox parts can be found in any number of industries, from paper to mining to cement. Its standard product lines include gear drives, Falk gear couplings and low-speed backstops.

Just as his dad helped make Milwaukee the beer capital of the world, Herman Falk helped make it a global center for manufacturing, earning the city a new title: “machine shop of the world.” Both helped make the Falk name synonymous with quality.

Original article can be found on Mar-Dustrial Sales’s website.


Problems with your Falk Gearbox?

Traditional sealing methods for the flooded shafts are inadequate resulting in oil leaking out of the gearbox creating an environmental and safety hazard.

Solution: The BPD-C from Orion Engineered Sealspicture of orion seals BPD-C

  • Incorporates all of the contamination exclusion features of the standard BPD
  • Designed specifically for flooded gearbox shafts.
  • Contains oil in vertical down as well as horizontal positions
  • Does not damage shaft
  • Provides an operating environment in which the contacting component of the seal to works effectively for years

Gallagher Fluid seals is a preferred distributor of Orion Engineered Seals. 

If you have questions about challenges you are facing in your plant,  contact the Gallagher engineering department.

Replacing a Desiccant Breather

Watch how easy it is to change out an Air Sentry GUARDIAN® desiccant breather on a gearbox.


Desiccant Breather - Air Sentry GUARDIAN®GUARDIAN® is Air Sentry’s industry leading breather series. Some models feature an isolation check valve that keeps exhaust air from depleting the desiccant and protects from volatile fumes and splashing fluids. The GUARDIAN’s casing is constructed from Tritan®, a patented material highly resistant to impact and chemicals with a broad range of operating temperatures. These unique features equate to a longer life for your breather and your equipment.

GUARDIAN’s modular construction and optional add-on features allow you to customize each Guardian model to your specific application requirements. From the isolation check valve, to its stackable design, from its wash-down cap, or its compound indicating gauge, to the high-capacity HEPA filter, the GUARDIAN® will last longer and reduce downtime giving you the flexibility you need to protect your industrial assets.

Protection for Flooded Gearbox Shafts

Orion Seals BPD-C - Gearbox ApplicationThe Orion Engineered Seals patented Bearing Protection Device (BPD) represents state of the art bearing protection technology and is the premier non-contacting bearing protection device offered. The BPD was designed with an understanding of the nature of the bearing housing environment under all operating conditions and utilizes the laws of physics to create what has proven to be the best performing and most cost effective way to protect the bearings of your rotating equipment.

The BPD-C Works in Flooded Environments

Orion Seals - Gearbox ApplicationProblem: Traditional sealing methods for the flooded gearbox shafts are inadequate, resulting in oil leaking out of the gearbox, creating an environmental and safety hazard.

Continue reading Protection for Flooded Gearbox Shafts

Air Sentry® Saves Manufacturer $340K

Air Sentry® - GearboxGearboxes are used on various types of industrial machinery to provide increased torque while reducing speed from one type of rotating power source to another using gear ratios. A gearbox can be set up to do the opposite and provide an increase in speed with a reduction of torque. Some of the simplest gearboxes merely change the physical direction in which power is transmitted.

Gearboxes are used in many applications, such as wind turbines, conveyors, draglines, bridges, wastewater treatment pumping systems, and many other large pieces of machinery that require a power source.

In an effort to cut costs and improve system reliability, a manufacturer of high quality construction materials examined maintenance costs of their fifteen facilities. One of the findings showed spending in excess of $650,000 annually to maintain and repair 500 gearboxes across all plants.

Continue reading Air Sentry® Saves Manufacturer $340K

VIDEO: GUARDIAN® Contamination Control Breather in Action

Air Sentry® set the industry gold standard with their first line of contamination control breathers in 1997, and now that standard is raised with GUARDIAN®.

Watch the video below to see how the Air Sentry® GUARDIAN® protects your process fluids from particulates and moisture.

Continue reading VIDEO: GUARDIAN® Contamination Control Breather in Action

Protecting Fluid Reservoirs from Contamination

Air Sentry® BreathersAir Sentry® breathers should be an integral part of any proactive maintenance and reliability program. The breathers are designed to replace the breather cap or air filter on gear boxes, hydraulic fluid reservoirs, bulk storage tanks, oil drums, oil-filled transformers, and other fluid reservoirs.  Most older style air venting methods provide minimal, if any, contamination control.  Air Sentry® breathers provide the first line of defense in contamination control methodology, utilizing patented designs and featuring color indication silica gel and self-cleaning 2-micron filtration.

Why is Contamination Control Important?

There are two important threats to productivity that an Air Sentry breather can protect you from:

Particulates
One research group found that greater than 75% of all machine wear related failures were due to particulate contaminants. Frequently the greatest cost of equipment failure is not the component replacement cost, but the labor production downtime. Most particles start off as dirt that becomes airborne, finds its way into lubricant and fuel reservoirs, and is later transported to bearings, bushings, seals, valves, and other machine components. There they become key ingredients in abrasion, erosion, and fatigue failures. The contaminants also cause lubricant degradation, shortening the life of the lubricant and decreasing its ability to lubricate.

Continue reading Protecting Fluid Reservoirs from Contamination