Future Gearing
Innovation in materials and engineering is redefining how gears and drives deliver power, efficiency and motion.
In the rapidly evolving world of industrial machinery and construction equipment, gears and drives have undergone a quiet but powerful transformation. No longer mere mechanical intermediaries, they are now sophisticated components engineered for precision, efficiency, and intelligence. As India accelerates its infrastructure build-out—from highways and metros to ports and industrial capacity—the demand for reliable, high-torque, high-efficiency power transmission solutions has never been higher.
Global technological advancements, local manufacturing capability, and the rising need for energy-efficient systems are reshaping the gears and drives landscape. What was once a space dominated by conventional gearboxes and standard motors has today grown into a sophisticated ecosystem featuring high-performance geared motors, advanced industrial gear units for cranes, digitalised drives, and sustainability-focused motor technologies.
Across the board—from OEMs and heavy industries to crane builders, material handling companies, and construction equipment manufacturers—there is a renewed focus on performance, energy savings, and operational reliability. Companies like Power Build, Nord Drivesystems, ABB, and global leaders tracked by Interact Analysis are shaping this next phase of growth. And even as the global market shows signs of deceleration, India and Southeast Asia are poised to inject momentum, driven by rapid industrial expansion and infrastructure investment.
Engineering precision
For any industrial system—be it a conveyor, mixer, crusher, hoist, or crane—its performance excellence is deeply linked to the capability and reliability of its gears and drives. At the core of modern systems lies an intricate balance between power density, energy efficiency, noise reduction, and mechanical durability. This balance has evolved considerably in recent years, thanks to advanced metallurgy, improved gear tooth geometries, and smarter integration with motors and electronic control systems.
A good example of precision engineering in this space is Power Build’s flagship geared motor portfolio encompassing the M, C, F, and K series. These geared motors represent a wide spectrum of mechanical configurations designed to meet the varied needs of industry—from compact inline solutions to high-torque, right-angle designs for heavy-duty applications.
The Series M helical inline geared motors, for instance, highlight how compact design can still deliver high performance, with power handling up to 160 kW and torque extending to 20,000 Nm. Their quiet operation and flexible mounting make them a preferred choice in manufacturing environments where operational stability and noise suppression matter.
Similarly, the Series C heli-worm geared motors offer right-angled transmission with exceptionally high gear ratios up to 16,000:1 and torque capabilities reaching 10,000 Nm. In industries where compact layouts collide with high torque requirements—such as food processing, small conveyors, or space-constrained machinery—such hybrid gearing solutions offer the best of both worlds.
Industrial environments that demand ruggedness—like steel plants, mining conveyors, or hoisting applications—lean toward stronger, endurance-focused systems. Power Build’s Series F parallel shaft mounted geared motors with torque delivery up to 10,000 Nm and gear ratios of up to 20,000:1 address these heavy-duty use cases. Meanwhile, for ultra-high torque right-angle operations in cement, power, and mining industries, the Series K helical bevel geared motors, capable of up to 50,000 Nm, reflect the engineering refinement and reliability that modern infrastructure applications demand.
What unites these portfolios is not just mechanical robustness but decades of experience in engineering design, performance optimisation, and application-oriented innovation. As manufacturing environments automate and construction equipment scales up, the demand for engineered geared motors capable of precision power transmission continues to intensify.
Crane systems demand specialised drive engineering
Cranes—whether used in ports, shipyards, steel plants, or manufacturing facilities—represent some of the most dynamic-load systems in industrial environments. Their repeated cycles of lifting, travelling, and cross movement place enormous stress on drive systems. This makes them a unique challenge for gear manufacturers, who must engineer solutions that combine high load-bearing ability, compact design, and resistance to complex stress patterns.
Nord Drivesystems has emerged as one of the leading innovators in this specialised segment. Its complete drive systems for crane applications integrate motors, scalable drive electronics, and powerful MAXXDRIVE® industrial gear units, which form the heart of crane motion mechanisms. Recognising that crane applications differ significantly between lifting and traveling operations, Nord has developed purpose-optimised gear units—the MAXXDRIVE® XD and MAXXDRIVE® XJ.
The MAXXDRIVE® XD is engineered expressly for lifting gears. Its elongated gear stage arrangement supports a U-shaped drive configuration with rope drum and motor positioned efficiently on the same side, while its housing design is tailored to withstand downward and external loads common in lifting operations. With a centre distance stretching up to 1,281 mm, it accommodates broad structural configurations while ensuring stable torque delivery.
On the other hand, the MAXXDRIVE® XJ is built for travel and cross-travel applications. Its distinctive J-shaped shaft configuration, with a vertical drive shaft and compact helical bevel stage arrangement, enables an extremely space-efficient design. In crane runways or industrial halls where installation space is at a premium, this architecture allows smoother design integration and system flexibility.
Supported by Nord’s rigid UNICASE housing and optional additions like drum couplings or brake consoles, these systems cater to crane builders seeking customised performance, reduced CO? emissions through efficient motors, and optimised weight distribution. Moreover, compliance with global standards—FEM in Europe, CMAA/ASME in North America, and IS standards in India—ensures operational safety and reliability.
The company’s global service network spanning 80+ countries further strengthens adoption, ensuring fast turnaround for maintenance and operational support—critical for applications where downtime directly translates to operational losses.
Market outlook
Despite technological momentum, the global geared products market is going through a period of contraction. According to Interact Analysis, after strong demand in 2022, the market saw a decline in 2023 and is expected to drop further by 1.9 per cent in 2024 before rebounding in 2025. Price hikes in 2022 driven by raw material costs, supply chain disruptions, and energy price volatility contributed significantly to revenue numbers, masking underlying volume softness.
APAC, which accounts for 46 per cent of the global market, saw the largest contraction in 2023—mainly because of China’s economic slowdown and its property market slump. However, India and Southeast Asia are expected to counterbalance this decline over the next few years, supported by infrastructure investments, manufacturing growth, and rising construction activity.
The Americas showed strong demand in 2022, growing 12 per cent, outpacing EMEA’s modest 1.1 per cent. Meanwhile, suppliers continue to consolidate—Regal Rexnord’s acquisition of Altra Motion places it among the top global vendors, while SEW Eurodrive retains the No. 1 position worldwide.
Despite global challenges, the long-term outlook is optimistic. From 2025 onwards, Interact Analysis predicts steady annual growth of 3–5 per cent, driven by automation, energy efficiency mandates, and heavy industry expansion—trends that align strongly with India’s growth trajectory.
Shift towards sustainability
India’s surge in infrastructure development—metros, highways, renewable energy plants, smart factories, and industrial corridors—is creating a robust market for motors, drives, and geared solutions. ABB India, one of the prominent players in the motion business, has witnessed a significant rise in demand across segments like crushers, manufacturing sand, HVAC, and e-mobility-driven applications.
According to Sanjeev Arora, President – Motion Business Area, India at ABB, the company’s portfolio spans low and high voltage motors, variable frequency drives, PLCs, traction motors for rail and e-mobility, and complete drive-motor packages. A strong emphasis is placed on customised solutions and energy-efficient products like the IE4 motor range, now extended up to 1 MW.
With HVAC systems alone consuming around 30 per cent of energy in large buildings, ABB’s high-efficiency motors and drives help customers significantly reduce operational costs and carbon emissions. The move toward energy conservation is not limited to large cities. Tier 2 and 3 locations—now industrialising rapidly—are emerging as major growth hubs. ABB’s channel partner network has expanded by 40 per cent, much of it from smaller cities.
Arora emphasises that India’s shift from IE2 to IE3/IE4 motors is crucial. IE3 motors offer 15–20 per cent lower losses than IE2, while IE4 motors further extend energy savings. Upgrading India’s MEPS (Minimum Energy Performance Standards) from IE2 to IE3 or higher could save up to 2.1 TWh annually—enough to power entire towns.
Sustainability is central to ABB’s strategy, with its manufacturing facilities already powered 100 per cent by renewable energy and holding top certifications from IGBC. Digitalisation is another major thrust area, enabling customers to optimise energy use, improve maintenance predictability, and integrate smart automation across operations.
The road ahead
Across the industrial landscape, one trend is unmistakable: gears and drives are becoming smarter, more efficient, and more application-specific. Mechanical durability will always remain fundamental, but the next wave of innovation is being driven by:
- Digitalised drives and motors capable of predictive analytics
- High-efficiency IE4/IE5 motors aligned with India’s decarbonisation goals
- Electrification of construction equipment, including cranes, compact machines, and mining vehicles
- Advanced material science for improved torque density and longer lifespan
- Custom-engineered gear units for cranes, hoists, and process industries
- Integrated motion packages combining motors, drives, control systems, and IoT platforms
As India pushes toward its infrastructure ambitions, the gears and drives sector will play an increasingly crucial role. Every crane that lifts, every conveyor that moves, every crusher that breaks rock, and every metro that runs depends on the silent, consistent performance of a gear or a motor.
The future of gearing is not just about transmitting motion—it is about transmitting it smarter, cleaner, and more efficiently than ever before. With global leaders advancing innovation and India emerging as a key growth engine, the industry is firmly moving toward a future where materials, mechanical engineering, and digital intelligence converge to redefine power transmission.
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