Standardised and custom products and solutions

For demanding applications, ZOLLERN offers standardised and custom products and solutions. They are aimed at the needs of the respective application areas and are successfully in use around the world.

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Castings for construction and construction machines
Castings for construction and construction machines

ZOLLERN manufactures resistant and precise castings for use in construction machines, such as roller bearing segments for tunnel boring machines.

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Castings for automotive industry
Castings for automotive industry

ZOLLERN produces complex and highly efficient components for the automotive industry, such as custom turbine wheels, flap plates, bushings, VTG vanes, finger followers, planet carriers, wheel carriers and housings for various application areas, such as turbochargers, engines, brake systems and drive trains.

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Castings for aviation
Castings for aviation

In many areas of aviation, investment castings from ZOLLERN ensure reliable technical functions. Lightweight design and highly-durable investment casting solutions are our speciality. 

ZOLLERN produces custom castings for use in fuselages, electronics, fuel systems and chassis, specialising in structural components, connecting elements, air inlets, water separators, rotary drive housings, fuel pumps, balance weights, brackets, pipe systems, pipe connecting elements, anti-rotation devices, brake drums, turbine wheels and stators. Even focusing in products for the model aircraft industry.

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Castings for energy
Castings for energy

The high-efficiency castings from ZOLLERN play an important role in systems for energy generation and distribution in the water, gas, coal, wind and nuclear industries.

  • ZOLLERN produces Francis runners, Turgo runners and Pelton runners as well as Kaplan blades for hydropower and also offers retrofitting.
  • Cage rings for wind power bearings are used in wind energy. 
  • For the coal, gas and oil sectors, ZOLLERN produces burner parts, blade support rings, blades for FGD fans, turbine blades and vanes for gas turbines, guide and rotor blades, heat shields, burner components, housings, drilling seals and highly complex drilling equipment for oil wells.
  • ZOLLERN burner rod holders are used in nuclear energy. 
  • In addition, ZOLLERN produces pole heads and pole supports as well as connectors for current guides and stator press rings for generators.
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Castings for maritime and offshore
Castings for maritime and offshore

The copper, steel and nickel-based alloy cast components impress in maritime applications with their corrosion resistance, geometric complexity and particularly high casting quality.

ZOLLERN produces hub housings, blades, fittings, valves and other castings for submarines, jack-up systems and other maritime applications.

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Castings for mechanical and plant engineering
Castings for mechanical and plant engineering

In almost every area of mechanical and plant engineering, the sophisticated casting solutions from ZOLLERN meet the highest requirements, such as housings, guides, mounts, chain links, grippers, tools, screw conveyors, fittings, agitators, brackets, levers or measuring elements.

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Castings for railway technology
Castings for railway technology

ZOLLERN produces resistant castings for railway technology, such as levers for tracked and rail vehicles.

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Castings for the electrical industry
Castings for the electrical industry

ZOLLERN produces custom castings for use in electrical and electronic engineering, such as connections and housings.

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Castings for military applications
Castings for military applications

ZOLLERN produces custom castings for military equipment and military technology, such as housings, brackets, guides and levers.

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Castings for medical technology
Castings for medical technology

ZOLLERN uses select materials to produce highly complex components for medical technology, such as knee, femur and tibia implants as well as surgical equipment, laboratory equipment and medical instruments.

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Castings for pumps
Castings for pumps

The copper alloy and steel alloy castings resist high pressures and are resistant to corrosion and abrasion. They are used in pumps on land as well as above and underwater, for example as a piston pump housing, spiral housing, impellers, impeller hubs, blades and wear rings in feed pumps, in cooling water pumps or in fire-fighting water pumps. In addition, ZOLLERN also produces castings for pumps in the food industry.

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Castings for arts
Castings for arts

ZOLLERN implements artist ideas in unique cast products. CAD and cast simulation applications as well as the wealth of experience in art casting result in high-quality steel casting and bronze casting components for sculptures, that meet very special quality requirements.

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Forging solutions for aviation
Forging solutions for aviation

ZOLLERN offers sophisticated component solutions and semi-finished products made of copper materials for the aviation industry, such as bushings, rings and rods for landing flaps and landing gear.

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Forging solutions for maritime and offshore
Forging solutions for maritime and offshore

ZOLLERN offers individual component solutions for maritime applications. Hub housings, fittings, propeller blades and semi-finished products for submarines, jack-up systems and other maritime and offshore components are made from ZOLLERN steel alloys and bronze alloys as well as ZOLLERN forged bronzes for offshore applications.

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Forging solutions for electronics and electrical engineering
Forging solutions for electronics and electrical engineering

ZOLLERN offers forged and ring-rolled component solutions for use in electric motors, railway motors, industrial motors and rotors, such as rings with a diameter from 200 to 1,600 mm, short-circuit rings, rotor rods, shrink rings and cap rings.

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Forging solutions for mechanical engineering, forming technology and mould making
Forging solutions for mechanical engineering, forming technology and mould making

ZOLLERN offers individual component solutions from copper-based materials for machines in sheet metal forming and solid forming, for injection moulding machines, packaging machines and other applications. The forged products include spindle nuts, bushings and other semi-finished products.

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Forging solutions for furnace construction
Forging solutions for furnace construction

Solid copper parts are used in electric furnaces when high currents flow or a very good thermal conductivity is required to cool individual areas.
ZOLLERN produces cooling floors, cooling rings, conductor tubes and thick busbars. In addition, ZOLLERN offers forged sheet metal plates for melting furnaces and heat treatment furnaces.

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Forging solutions for cooling technology
Forging solutions for cooling technology

The high thermal conductivity of pure copper and low-alloyed copper alloys is used for heat sinks. ZOLLERN offers forged parts for cooling technology, such as for dies in continuous casting and wire rod plants, components for welding systems, parts for accelerators in research and medicine, for rocket nozzles, heat exchangers, cooling plates and heat sinks in general, as well as for the high vacuum range in research facilities.

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Gearboxes for maritime and offshore
Gearboxes for maritime and offshore

ZOLLERN gearboxes are used in almost all maritime applications; on ships, in ports or on offshore platforms. 
Typical application areas are ship cranes, floating cranes, dredgers, lifeboat winches or jack-up gearboxes for offshore platforms. ZOLLERN gearboxes, for example, move mobile harbour cranes, shipyard cranes, handling equipment and container stackers on land.

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Gearboxes for construction and construction machines
Gearboxes for construction and construction machines

ZOLLERN gearboxes are used in almost all construction equipment applications. 
Typical applications are mobile cranes, lattice boom cranes or tower cranes, drilling rigs, cable excavators, crawler excavators, dump and reloading equipment and concrete pumps. In addition, ZOLLERN specialises in highly stressed drive components, such as those used in road milling machines, bucket wheel excavators or tunnel boring machines.

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Gearboxes for mining and conveyor technology
Gearboxes for mining and conveyor technology

ZOLLERN gearboxes can be found in various sectors for mining technology and bulk material handling, such as in mining excavators or in take-up systems for conveyor equipment. In addition, extruders or calendars are driven by ZOLLERN drive technology.

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Gearboxes for energy and raw material extraction
Gearboxes for energy and raw material extraction

ZOLLERN gearboxes are used in various industrial applications in energy and raw materials production.
Typical applications are oil platforms, mining excavators, dump and reloading equipment, bucket wheel excavators, tensioning systems for conveyor systems or pitch and azimuth gears for wind turbines.

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Winches for maritime and offshore
Winches for maritime and offshore

ZOLLERN winches are used in almost all maritime applications; on ships, in ports or on offshore platforms. 

Typical application areas are ship cranes, mobile harbour cranes, heavy-duty cranes, shipyard cranes, offshore cranes, port handling equipment, container stackers, dredgers and rescue systems.

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Winches for construction and construction machines
Winches for construction and construction machines

ZOLLERN offers winches for many construction machine applications, such as cranes, mobile cranes, tower cranes, crawler cranes, lattice boom cranes, drilling rigs as well as duty cycle crawler cranes and crawler excavators.

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Winches for industrial applications
Winches for industrial applications

ZOLLERN winches perform their work reliably in many industrial sectors, for example in tensioning systems for conveyor systems or in process and indoor cranes.

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Winches for mining and conveyor technology
Winches for mining and conveyor technology

ZOLLERN winches perform reliably in conveyor belt systems in various fields of application, such as in mining and industry.

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Special profiles for linear technology
Special profiles for linear technology

ZOLLERN produces linear profiles with high wear strength, high load capacities and good hardenability with simultaneously low distortion in further processing. Inductive hardening is used to achieve partially high surface hardness of up to 64 HRC in the edge area. 

ZOLLERN linear profiles are used as ball and roller guides, miniature rails, heavy-duty rails, telescopic rail guides, shaft supports or linear axes in automation, measuring systems, heavy-duty applications, parcel logistics and in transport.

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Special profiles for vehicle construction
Special profiles for vehicle construction

ZOLLERN steel profiles are used in almost all areas of vehicle construction. 

As profiles for engine and injection systems, connection components for fluid lines, adjustment systems, steering systems, safety systems, in gearbox and pump technology, for example for vane pumps, as well as for component for e-mobility. 
The special profiles help to control emissions as components and support exhaust systems as flap profiles. As splined shafts and solenoid valves, they work in brake systems, they serve as locking bolts in steering wheel locks or serve as counterweights for vehicle stabilisation.

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Special profiles for railway technology
Special profiles for railway technology

From components in passenger transport to profiles for securing platforms and tracks using screen doors, ZOLLERN steel profiles offer very high dimensional accuracies and an optimal strength ratio with a simultaneously high surface quality. They are ideal for diverse applications in rail transport.

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Special profiles for mechanical and plant engineering
Special profiles for mechanical and plant engineering

ZOLLERN steel profiles reliably perform their duty in various areas of mechanical and plant engineering. They work in machine tools, pressure machines and pumps, including as clamping jaws, pneumatic clamping elements, clamping bodies for freewheels, gear profiles for shafts or as scrapers and chip deflectors.
They are used as folded profiles for machine covers, gripper profiles in robotics, sliding blocks in assembly systems, as splined or polygonal shafts, as thread guides, deflection aids and needle rails in textile machines or as guide rails and clamping bars.

There are many possible applications of the precisely shaped profiles.

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Special profiles for locks and fittings
Special profiles for locks and fittings

Large series can be economically implemented by using steel profiles for locks and fittings. They are used as pinion profiles or half-pinions for door locking systems, as door openers, door stoppers, housings for padlocks, profiles for door and window locks, as special profiles for sliding blocks and as drive shafts in blinds and roller shutter drives.

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Special profiles for power engineering, generator construction and electric motors
Special profiles for power engineering, generator construction and electric motors

Flawless surfaces and excellent mechanical properties characterise the profiles. As keybars, press fingers, dovetail bars and I-T-bars and double T-bars as well as pole shoe profiles in generator construction and electric motors, they ensure functional reliability and durability in the application.

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Special profiles construction and construction machines
Special profiles construction and construction machines

ZOLLERN profiles are used as kelly profiles for kelly bars in drilling technology as well as special profiles for scaffolding and façade construction, as hydraulic pump housings and drop profiles for shafts in forklift attachments as well as edge formwork profiles (filigree strips) for concrete formwork systems.

There are many possibilities for special profiles and resulting prefabricated finished parts.

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Special profiles for weapons technology
Special profiles for weapons technology

ZOLLERN steel profiles are an economic alternative to traditional production technologies in the hunting and sporting guns industry.
The precisely pre-formed profiles are used to produce breech blocks, slide blocks, triggers, hammer blocks, gas pressure loaders, shaft profiles, sight rails and other products that have been proven in use for hunting and sporting weapons, for example in small arms, long firearms or even shafts for tank tracks.

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Special profiles for medical technology
Special profiles for medical technology

ZOLLERN special profiles are aimed at the high standards in medical technology. They offer an excellent surface quality and are made of high-quality materials, as well as in implant quality.

The profiles are ideally suited for medical technology parts and devices, for example as bone nails and fixations as well as precision profiles for implants or as ceiling rails for medical technology devices.

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Special profiles for textile machines
Special profiles for textile machines

ZOLLERN steel profiles work reliably in flat knitting machines, circular knitting machines, spinning machines, weaving machines, knitters and carding machines. 
They provide quick and precise movements, for example as take-off rollers, yarn guides, deflection aids, needle rails, slide rails or as under-apron bridge elements.

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Special profiles for shredding and recycling
Special profiles for shredding and recycling

Steel profiles are used for recycling, keeping clean and crushing in various forms, such as blade holders, chopping blades, clamping bars, cutting bars, chip deflectors or as rake profiles for sewage treatment plants.

The precisely pre-formed profiles are suited for agricultural and forestry, the paper industry as well as for the waste and recycling industry.

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Special profiles for splined shafts
Special profiles for splined shafts

ZOLLERN supplies splined shafts from tempered steel for universal joints and special profiles according to the relevant standards, such as DIN ISO 14. 

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Special profiles for agricultural machines
Special profiles for agricultural machines

ZOLLERN supplies high-quality steel profiles and finished parts made from steel profiles for use in agricultural machines, such as blade holders for chippers and shredders.

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Guide shafts and flat guide rails for vehicle construction
Guide shafts and flat guide rails for vehicle construction

ZOLLERN semi-finished products are processed further and used in various areas of vehicle construction, for example in injection pumps, throttle solenoid valves, injectors, spring struts and shock absorbers. 
They reliably do their job as piston rods, chrome tubes, axles, bolts, shafts or as machined profiles.

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Guide shafts and flat guide rails for agricultural machines
Guide shafts and flat guide rails for agricultural machines

ZOLLERN shafts and flat guide rails are used in loading wagons, choppers, combine harvesters and presses as axles, pins, drive shafts, guide shafts or piston rods.

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Guide shafts and flat guide rails for machines and systems
Guide shafts and flat guide rails for machines and systems

ZOLLERN supplies shafts and guide rails for various machines, such as rubber and plastics machines, printing machines, woodworking machines, assembly and handling technology, foundry machines, machine tools and straightening machines. 

The products range from guide columns, tie bars, flat guides, ejector pins, axles, bolts, drive shafts to piston rods, rollers and profiles.

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Guide shafts and flat guide rails for linear technology
Guide shafts and flat guide rails for linear technology

For linear technology, ZOLLERN supplies ready-to-install components such as flat guide rails, shafts, hollow shafts and profiles from prefabricated semi-finished products. 
These are used in line gantries, surface gantries, multi-axis gantries, robots and as round guides and flat guide rails.

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Guide shafts and flat guide rails for construction machine
Guide shafts and flat guide rails for construction machine

The applications and materials of ZOLLERN shafts and flat guide rails for construction machines are varied. For example, they are used as piston rods, bolts, hinge pins, pump pistons, shock absorber tubes and axles in excavators, wheel loaders, concrete mixers, cranes, trucks or dump trucks.

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Direct drives for machines and systems
Direct drives for machines and systems

The torque motors and synchronous motors from ZOLLERN are primarily used in

  • machine tools driving tilting type rotary tables and spindles for example,
  • plant construction and industrial applications such as extruders, centrifuges, eccentric presses, sugar cane mills, shredder or mixer drives,
  • and in combination with planetary gearboxes and winches from ZOLLERN. 
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Direct drives for maritime and offshore
Direct drives for maritime and offshore

ZOLLERN develops and manufactures direct drives for thruster drives or jet rudder drives of ships as well as synchronous motors that drive ZOLLERN cable winches in different crane systems, which are used in ports, on offshore platforms and ships or pontoons.

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Direct drives for power engineering
Direct drives for power engineering

ZOLLERN develops and produces torque motors for use in agitators and mixers in energy technology for biogas production.

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Direct drives for construction machines
Direct drives for construction machines

As one of the leading manufacturers of drill head drives, ZOLLERN develops and produces highly integrated synchronous motors specifically tailored to the application for use in tunnel boring machines. The drives are characterised by their power density and extremely short overall length. The service-friendly layout and the rugged design help to avoid downtimes.

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Automation and special systems for vehicle construction
Automation and special systems for vehicle construction

ZOLLERN develops and realises automation and handling solutions that are used in vehicle construction as conveyor systems, lifters, traversing axes or framing systems. 

These include, for example, transfer units with scissor-type jacks, roof tools, rapid conveyors, press feeders, lift stations, floor lifters, tool axes, robot axes, GEO clamping frames, tool storage and top transfers. 

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Automation and special systems for mechanical and plant engineering
Automation and special systems for mechanical and plant engineering

ZOLLERN develops and realises automation and handling solutions that are used in mechanical and plant engineering as line gantries, area gantries, machining gantries or handling systems.

The solutions are individually tailored to different applications such as manufacturing and assembly technology, construction industry, the lumber industry, plastics industry, glass industry, solar industry, consumer industry, beverage industry, surface treatment, press automation, welding, heat treatment, logistics and other applications such as loading, unloading and storage of tools and workpieces.

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Hydrostatic bearing systems for machines and systems
Hydrostatic bearing systems for machines and systems

ZOLLERN develops and produces hydrostatic bearing systems, such as hydrostatic radial bearings, axial bearings, combined radial-axial bearings, linear guides, rotary tables and rotary table bearings, guide units and spindles.

These are used in grinding machines, turning machines, milling machines and ECM machines, paper machines, printing machines, mills and presses of various designs, as well as test benches and various special machines.

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Rotary table systems for precision mechanical engineering
Rotary table systems for precision mechanical engineering

ZOLLERN develops and produces hydrostatic, aerostatic and anti-friction bearing-mounted rotary tables for use in machine tools such as turning machines, grinding machines, milling machines as well as for measuring machines and special purpose machines.
Depending on the machine concept, the rotary tables can be designed for vertical and horizontal installation, both as swivel rotary tables.

In addition, ZOLLERN offers a global service for rotary tables of the brands ZOLLERN, Rückle and Eimeldingen.

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