BMG has recently introduced the Next Generation Hansen I4 Industrial Gear Units (IGUs) which have been developed for safe and efficient use in tough mining and conveying applications.
These compact, invertible Hansen I4 units are engineered to deliver high torque capacity, dimensional accuracy and operational reliability in both underground and surface applications, while ensuring minimal maintenance requirements and extended service life.
Important advantages of the Next Generation Hansen I4 programme – which combines cost optimisation with retained design integrity – include reduced lead times and OEM-backed technical support throughout Africa.
“By standardising the core materials required in key Hansen I4 models, we are able to improve supply efficiency, while maintaining the original torque ratings, gear geometry and bearing performance required for heavy-duty mining and conveying applications,” explains Barry Stoltz, BMG’s Gears Regional Manager, Electro-Mechanical division.“The result is a robust and reliable unit that conforms with Hansen’s global design standards and technical specifications, but with improved availability for operations throughout the African continent.
“BMG has streamlined production and supply processes, reducing delivery lead times to a maximum of four weeks. This shorter turnaround time supports plant uptime strategies for our customers, where conveyor availability is directly linked to output and revenue.”
The revised I4 platform incorporates a standardised bill of materials across the core RDD, RDE and RDF configurations, with gear ratios between 16:1 and 35:1. This rationalisation enables bulk procurement of critical components, including bearings, seals, spacers, nilos rings, bolts and nuts. As a result, accessibility and cost-efficiency are improved, with no compromise on performance, even in arduous conditions. Local sourcing further strengthens supply continuity for the African market.
The Hansen I4 is built around precision-manufactured helical gearing and designed to AGMA-rated standards to balance high torque density with controlled noise levels. High torque geometry is applied to low-speed gears, while high-speed stages are configured to reduce noise emission. Detailed service factor and operating life calculations underpin the shaft and bearing design, ensuring suitability for continuous-duty conveyor and mining drives.
Installation flexibility is a core feature of the Hansen I4 range. The gearbox can be inverted through 180 degrees to accommodate left- or right-hand drive arrangements, reducing inventory requirements and simplifying plant layout. A robust horizontally split housing facilitates easy inspection and maintenance, while horizontal or vertical shaft configurations provide adaptability for different mechanical interfaces. Hansen’s Oil-Lock sealing arrangement ensures long-term oil retention and reduced contamination risk in abrasive environments.
As the official OEM for Hansen gearboxes in Southern Africa, BMG is authorised to repair Hansen IGUs in accordance with the manufacturer’s documented procedures, maintaining original tolerances and operating specifications. Every unit undergoes detailed incoming inspection, full disassembly and dimensional verification of housings, shafts and gears before reassembly to factory-defined clearances. Bearings and seals are replaced as standard, fasteners are torqued to specified values and gear contact patterns are verified to meet correct mesh alignment requirements.
No gearbox is released before a controlled running test confirms mechanical, thermal and lubrication performance, including checks on temperature, noise and oil tightness.
BMG’s Next Generation Hansen I4 range meets the requirements of customers seeking a standardised, high-torque cost-efficient IGU, with reduced lead times and local OEM-backed technical support.
