Industries

Mining industry
Brand introduction

Edition April 2016

CONTENTS

Solutions for mining applications .................................................... 4

Crushers & feeders ....................................................................... 6
Conveyors ..................................................................................... 8
Stockyard equipment .................................................................... 10
Solid/liquid separation ...................................................................12
Port equipment ............................................................................. 14
Experience ....................................................................................... 16
Our experience in mining .............................................................. 16
Experience and knowledge means ............................................... 17
Offering ............................................................................................ 18
Proposals based on engineered solutions .................................... 18
Some of our references ............................................................... 19
Rossi Special Projects ...................................................................... 20
Dedicated team + specific job = Project Management................. 20
Order phase ..................................................................................... 21
Customer order management ....................................................... 21
Quality and Products ....................................................................... 22
Helical and bevel-helical gear reducers and gearmotors .............. 22
Rossi Special Projects for mining industry ....................................22
Heavy industry products for mining industry ................................23
Drive units on swing bases ........................................................... 23
Modularity means competitiveness .............................................. 24
Example of modularity .................................................................. 25
Cutting edge technology .............................................................. 26
Quality control ...............................................................................27
Specialized housing machining .....................................................28
Test controls .................................................................................. 29
Service ............................................................................................. 30
Global partnership for local solutions ........................................... 30
Global service ............................................................................... 31
Our service centers worldwide ..................................................... 31
SOLUTIONS FOR MINING APPLICATIONS

With over 60 years experience in the design, manufacturing and

commissioning of gear reducers and gearmotors, Rossi has become a
power transmission leader in the mining sector.
Rossi has forged many strategic partnerships with established mining
companies and original equipment engineering firms in this sector and
throughout the world. Relationships forged from Rossis know-how
and expertise in many different industries combined together allow the
company to offer turn-key solutions for nearly every mining application.
Rossis smart solutions, thanks to product designed around modularity,
robustness and reliability, help customers to minimize Total Cost of
Ownership of plants, reducing maintenance costs and risk of process
downtime as well as enhancing energy saving.

4
CRUSHERS & FEEDERS CONVEYORS STOCKYARD

SOLUTIONS FOR CRUSHERS & FEEDERS

Rossis comprehensive product range offers some of the best mechanical

performance in terms of torque to mass ratio, thermal capacity and
reliability, enablings Rossis products to outperform competitors in
applications such as crushers, belt feeders and conveyors.
Rossis smart design, robustness and reliability reduce downtime, lower
maintenance cost and enhance energy saving giving plant operators a
low cost smart solution.

6
EQUIPMENT SOLID / LIQUID SEPARATION PORT EQUIPMENT

SOLUTIONS FOR SOLUTIONS FOR SOLUTIONS FOR

CRUSHERS BELT FEEDERS APRON FEEDERS

Type: Helical gear units Type: Planetary in-line gear / Type: Planetary in-line gear /
Catalog: G, H Combined with bevel helical Combined with bevel helical
Catalog: EP, G Catalog: EP, G
CRUSHERS & FEEDERS CONVEYORS STOCKYARD

SOLUTIONS FOR CONVEYORS

Mining raw materials is becoming more challenging as mineral deposits

become more remote. The distance between the mine pit and the
processing plant could mean that large distances need to be spanned,
while extraction times and product reliability have never been more
important.
Belt conveyors remain one of the most cost effective solutions as they
allow for large volumes of material to be transferred across most terrains
and gradients. Rossi has developed products perfectly tailored to belt
conveyors for harsh applications like those in the mining sector irrespective
of the conveyor or terrain they need to operate in.

8
EQUIPMENT SOLID / LIQUID SEPARATION PORT EQUIPMENT

SOLUTIONS FOR SOLUTIONS FOR SOLUTIONS

CONVEYORS CHAIN CONVEYORS FOR OVERLAND
CONVEYORS

Type: Bevel - helical gear units Type: Bevel helical gear units Type: Bevel - helical gear units
Drive units on swing base Catalog: G Drive units on swing base
Catalog: RE Catalog: RE
 CRUSHERS & FEEDERS CONVEYORS STOCKYARD

SOLUTIONS FOR STOCKYARD EQUIPMENT

Stacker reclaimers, bucket wheel and circular stackers can be found in many
bulk handling stock yards and mines throughout the world.
Their principle function is to move large quantities of raw materials reliably,
continuously and of course cost effectively.
Rossi can provide specific drive solutions tailored to individual requirements
such as those found in bucket wheel excavators. With its specific solution, Rossi
customers can take advantage of both the benefits each type of gearing has to
offer: outstanding overload capacity of planetary and the highest mechanical
to thermal power ratio of bevel helical gear. The high torque to mass ratio
offered by our EP series planetary gear units provide significant benefits to
chains drives, conveyor belts and powertrains. Being modular they provide even
more benefits when combined with Rossis bevel-helical gear units to form a
combination drive package solution for use in high torque, high shock load
applications, typical of large bucket wheels.
The Rossi range allows for a high level of flexibility through optional accessories
and auxiliary equipment, which means cost can be controlled and every product
engineered to suit individual needs both technically and commercially.

10
EQUIPMENT SOLID / LIQUID SEPARATION PORT EQUIPMENT

SOLUTIONS FOR SOLUTIONS

BUCKET WHEEL FOR CIRCULAR
STACKER RECLAIMER STOCKYARDS

Type: Planetary in-line gear / Type: Bevel helical gear

Combined with bevel helical Catalog: G
Catalog: EP, G
 CRUSHERS & FEEDERS CONVEYORS STOCKYARD

SOLUTIONS FOR SOLID / LIQUID SEPARATION

There is a growing need to use more water through mining and other
industrialization processes. However with global water reserves being put
under more pressure than ever before, the need to manage waste water
effectively has never been more important. Every part of the process is
being tightly controlled and regulated to ensure proper environmental
controls are being adhered to. From clean drinking water to the residual
waste material every process requires a drive that will ensure reduced cost
of ownership through every process. Today, every process is considered
part of the solution as very often what was once waste is now a critical
component of another process. Sewage sludge for example is an organic
and renewable fuel source that can be used to power the installation
energy requirements. Looking back at more than 60 years of Rossi know
how and strategic partnerships in the management of waste water, Rossi is
able to offer the right drive solution for almost every waste water process.

12
EQUIPMENT SOLID / LIQUID SEPARATION PORT EQUIPMENT

SOLUTIONS FOR SOLUTIONS FOR

FILTERS FLOATATION CELLS

Type: In line combined Type: In line planetary gears

planetary gears Catalog: EP
Catalog: EP
 CRUSHERS & FEEDERS CONVEYORS STOCKYARD

SOLUTIONS FOR PORT EQUIPMENT

Port equipment from port container cranes, bulk ship loaders and various
other equipment needed to manage the daily movement of import and
export goods have become the gateway to individual countries economies.
Without the effective management of port equipment the industrial trade
between countries will become less efficient. Port authorities have limited
berths within ports to enable the loading and unloading of vessels, these
berths are charged per hour so the vessel operators demand that port
equipment operates fast, continuously and very reliably. As a principle
supplier to original manufacturers in the marine and specifically port
side equipment, Rossi smart solutions, are designed around modularity,
robustness and reliability, to ensure proper Total Cost of Ownership of port
equipment, reducing maintenance costs and enhancing load cycle times.
Thanks to Rossis reliable products many more vessels leave port on time.

14
EQUIPMENT SOLID / LIQUID SEPARATION PORT EQUIPMENT

SOLUTIONS FOR SOLUTIONS FOR

SHIP LOADERS SHIP UNLOADERS

Type: Helical - Bevel helical Type: Combined units Bevel

gears helical - Planetary gears -
Catalog: G, H Helical - Bevel helical gears
Catalog: EP, G, H
 EXPERIENCE OFFERING ROSSI SPECIAL PROJECTS

OUR EXPERIENCE IN MINING

With more than 60 years of know-how and experience in applications

within the mining sector, Rossi continues to design products for use in
heavy duty applications such as those found in mining, quarrying, mineral
processing and other typical applications. Rossi continues to develop its
working relationship with key global mining operators. This relationship
is built on trust, industry know how, industry competence and continued
investment in the product design and production techniques.
For over 60 years Rossi has understood that experience in this sector is a
key factor to develop solutions for the future.

16
 ORDER PHASE QUALITY & PRODUCTS SERVICE

EXPERIENCE AND KNOWLEDGE MEANS...

Experience and knowledge does not only mean to know what is needed
in the specific application, but also how to support customers during all
design and dimensioning phases.
Rossi continues to develop its experience and ensure it has the ability to
share vital knowledge that is relevant to machine builders today no matter
what the application is, information Rossi makes available includes
- expected bearing life calculation,
- Finite Element Analysis
- torque calculation, and
- shared design capabilities with customers
Why not discuss your application with a Rossi technician and ensure you
receive the benefit of Rossi experience in your application?
 EXPERIENCE OFFERING ROSSI SPECIAL PROJECTS

PROPOSALS BASED ON ENGINEERED SOLUTIONS

A Rossi proposal is a comprehensive document, designed to answer all the

questions posed through a customer enquiry and to ensure a comprehensive
summary is given to all the listed parameters of the design.
A proposal contains all the technical features and benefits needed to ensure
a Rossi units out performs any other unit in the market as it is selected as
closely as possible to the actual needs of the design. Used correctly, it answers
all the questions the decision makers need when evaluating a technical and
commercial proposal. Rossi believes that customers require a comprehensive
list of the objectives of the needs of the enquiry, this ensures all important
aspects are covered and written down form which to reference when
developing a viable solution. Having the customers objectives allows Rossi to
ensure all these are met and make recommendations in order of priority for
every customers.
With a Rossi proposal, customers get peace of mind as any service or warranty
is build into the service offering. Our warranty is comprehensive and arguably
one of the best on offer today. This is because we at Rossi believe in our
products and believe in our ability to meet the needs of our customers and we
are therefore willing to back it up.

18
ORDER PHASE QUALITY & PRODUCTS SERVICE

SOME OF OUR REFERENCES

CUSTOMER NAME APPLICATION

Tenova Group Material handling conveyors
Continuous ship unloaders
Radial stackers
Circular stockyards
Belt conveyors
Pipe conveyors
FLSmidth Group Apron feeders
Belt feeders
Overland conveyor drives
Inching Drives for Mill
Rotary kiln
Rotary sluice drives
Cement separator drives
Twin shaft brakers
Travel drives for mobile stacking conveyor
Mobile overland tripper
Metso Apron feeders
Portal reclaimers
Slurry pump drives
Rail car positioners
Linear stackers
Radial stacker reclaimers
Takraf Scraper reclaimers
Belt conveyors
Taim Weser Refinery machines
Thyssen Krupp Belt reel drives

END USER NAME APPLICATION

First Quantum Minerals Belt conveyors
Feeder drives
Overland conveyors
Apron feeders
Anglo American Belt conveyors
Gol E Gohar Material handling conveyors
Belt conveyors
Mongolyn Alt Group Apron feeders
Conveyors
Ausenco Conveyors
Rio Tinto Belt conveyors
Freeport Mc Moran Apron feeders
 EXPERIENCE OFFERING ROSSI SPECIAL PROJECTS

DEDICATED TEAM + SPECIFIC JOB = PROJECT MANAGEMENT

Once the order is assigned, our dedicated team, named Rossi Special
Projects, with specific and skilled resources, is in charge to develop the job
as a project. The Team Leader compiles the Job Quality Plan (document
PP28), identifies the critical phases and continues with the identification of
the main responsibilities.
The implementation of all the activities, as well as the collection and care of
Documentation, ensures that all the phases/activities already planned are
under control.

20
ORDER PHASE QUALITY & PRODUCTS SERVICE

CUSTOMER ORDER MANAGEMENT

Rossi ensures that all processes within the IT platform are designed
with rapid transfer of data needed for internal processes as well as for
the management of the order by the customers themselves. Rossi has
chosen to operate with Oracles JD Edwards EnterpriseOne. This facilitates
order management on one platform for both the customer and Rossi
staff anywhere in the world. Through a standard operating platform we
are able to configure customers unique forecasting, shipping standards,
transportation sequence and reporting processes in coordination with
commercial contracts and associated quality control documentation all
integrated to one ERP system.
 EXPERIENCE OFFERING ROSSI SPECIAL PROJECTS

HELICAL AND BEVEL-HELICAL GEAR REDUCERS

AND GEARMOTORS

BEVEL-HELICAL GEAR REDUCERS AND GEARMOTORS

G SERIES

Size 18 sizes (40 ... 360)

Power P1 0.09 ... 160 kW
Nominal torque TN2 87,500 N m
Transmission ratio iN 2 ... 160

HELICAL GEAR REDUCERS AND GEARMOTORS

G SERIES

Size 18 sizes (40 ... 360)

Power P1 0.09 ... 160 kW
Nominal torque TN2 87,500 N m
Transmission ratio iN 2 ... 160

ROSSI SPECIAL PROJECTS FOR MINING INDUSTRY

ROSSI SPECIAL PROJECTS

Power P1 according to specifications

700,000 Nm
Nominal torque TN2

Transmission ratio i according to specifications

22
ORDER PHASE QUALITY & PRODUCTS SERVICE

HEAVY INDUSTRY PRODUCTS FOR MINING INDUSTRY

HEAVY INDUSTRY PRODUCTS

EP SERIES
Size 10 sizes (1253000)

Nominal torque TN2 125,000 ... 3,000,000 Nm

Transmission ratio iN 18 ... 1,800

HEAVY INDUSTRY PRODUCTS

EP COMBINED UNITS
Size 6 sizes (125710)

Nominal torque TN2 710,000 Nm

Transmission ratio iN according to specifications

HEAVY INDUSTRY HELICAL AND BEVEL HELICAL

GEAR UNITS
H SERIES
Size 11 sizes (400 ... 712)
Nominal power PN2 16 ... 3,650 kW
Nominal torque TN2 630,000 N m
Transmission ratio iN 8 ... 315

DRIVE UNITS ON SWING BASES

DRIVE UNITS ON SWING BASE

RE SERIES
Gear reducer sizes 140 ... 712
Motor sizes 132 ... 400
Nominal torque TN2 630,000 N m
 EXPERIENCE OFFERING ROSSI SPECIAL PROJECTS

MODULARITY MEANS COMPETITIVENESS

Modularity can be considered the foundation of Rossi.

Modular products and modularprocesses allow Rossi to engineer a
solution for almost every industrial application requiring a gearmotor
or gear reducer. To Rossi, modularity means flexibility, wide range of
options, faster delivery, and most important of all, competitiveness.
Even more it allows for assemblies in any assembly facility with almost
limitless configurations allowing Rossi to deliver solutions, regardless if it
comes to supply a standard unit or an engineered one, in a cost effective
manner.
This capability is made possible through Rossis ability to understand
the customers requirements and translate the needs of that customer
into a commercially and technically acceptable solution. Of course, at
Rossi, our modular approach doesnt stop at the delivery of a product
or solution. For Rossi this is just the start, with strong online support
systems our customers have access to leading interactive product and
service care.

24
ORDER PHASE QUALITY & PRODUCTS SERVICE

EXAMPLE OF MODULARITY
 EXPERIENCE OFFERING ROSSI SPECIAL PROJECTS

CUTTING EDGE TECHNOLOGY

When it comes to high-performance and ground precision gear

manufacturing, technology and experience are everything.
Cutting edge technology without experience can limit the benefit
the final product has for the end user which is why Rossi continues
to take pride in the fact that the ground gears the company
manufactures are probably some of the best industrial gears
manufactured by anyone today.
Rossi believes that ground gears, be they helical gears or helical
bevel gears or any other, need to be of a consistent high quality
finish in order for Rossi products to maintain the reputation of quality
and performance they have today.
Cutting edge technology is also a fundamental corner stone of the
quality control procedures needed to ensure the strict standards
set as a company continue to be met and that the final product the
customer sees is never compromised. Cutting edge technology can
be bought, but how you control it is earned through experience.

26
ORDER PHASE QUALITY & PRODUCTS SERVICE

QUALITY CONTROL

Every Rossi component machined individually or part of a

production batch, follows a stringent quality control process as
part of Rossi Quality management policy. This policy is mirrored
in every Rossi production facility and is managed through a
dedicated in house IT system, that allows the rapid flow of
information at any given time. Rossis quality control policy,
audited by TV Nord, ensures that the manufacturing process is
controlled from the sourcing of material, all the way through the
final assembly of the geared product. Continuous monitoring of
the ISO 9001 manufacturing procedures and processes allows the
production quality control process to eliminate excess costs that
could traditionally be added to the final batch of any production
run, ensuring a cost effective final product. Rossi employs
some of the most modern quality control equipment needed to
measure tooth profiles, surface finishes and critical dimensions of
components. Rossi by employing this quality management plan,
can ensure consistent product performance safe in the knowledge
that Quality is the foundation Rossi products are built on.
 EXPERIENCE OFFERING ROSSI SPECIAL PROJECTS

SPECIALIZED HOUSING MACHINING

High performance needs to be supported with important

equipment and knowledge.
For this reason, Rossi dedicates special attention to machining
all components, including housings for big sizes. High quality
standard requirements can be reached using cutting edge
technology, such as our new boring milling center.
Production flow is complete with the final operation and quality
check. The housings are measured using appropriate Coordinate
Measuring Machines (CMM). One of our CMM machines can
be used also as gear inspection system, offering the possibility to
check parts with the following maximum dimensions:
length 4000 mm, height 2000 mm, width 2000 mm.

28
ORDER PHASE QUALITY & PRODUCTS SERVICE

TEST CONTROLS

Systematic, extensive controls on every stage of the process

(from materials to final controls under load using computerized
brakes at the end of the assembly line) and their productivity
allow quality to be produced and not just achieved through
selection, and permit monitoring and improving the process
itself.
In addition customers can trust our solutions which have been
fully tested and run in our testing room, being operationally
certified before on site commissioning.
 EXPERIENCE OFFERING ROSSI SPECIAL PROJECTS

WHERE WERE LOCATED

Subsidiaries
Distributors / Dealers

GLOBAL PARTNERSHIP FOR LOCAL SOLUTIONS

As a result of the rapidly growing importance of the global

market for power transmission systems, Rossi has set up a network
of subsidiaries and dealers in nearly all industrialized countries.
Support during the design phase, local availability of the required
drive technology and rapid local service make Rossi a flexible and
dependable partner throughout the world.
Cooperation with Rossi is especially customer-friendly and efficient
with Rossiforyou - a communication network which provides
a 24/7 global coordination of the ordering, supply and service
processes.

30
ORDER PHASE QUALITY & PRODUCTS SERVICE

GLOBAL SERVICE

We dont stop with the sale of our product, we provide our

customers with service and back-up.
Through our subsidiaries stocks and assembly centers worldwide
we make sure that we are not only able to supply gearboxes but
that we can also back them up, if need be, with the spare parts
required.
Our Global Service has the possibility to reach our customers
plants quickly, in case of breakdown. Our main goal is to return
our customers plants to operation as soon as possible and to
keep maintenance overheads as low as possible.

OUR SERVICE CENTERS WORLDWIDE

AFRICA phone +27 32 815 0380

AMERICA phone +1 800 931 2044
ASIA phone +86 21 3350 5345
EUROPE phone +39 059 330288
OCEANIA phone +61 8 94557399
 FSC
Every decision we make at Rossi impacts the world we live in. But new technologies and renewed commitment to
sustainable practices have provided us with the opportunity to make environmentally friendly printing decisions.
Our catalogs are printed on Forest Stewardship Council (FSC) certified paper (1).
This is our tangible commitment in terms of environment sustainability.

(1)
The certification means that finished wood-based products in the marketplace have been handled by companies that have also been certified
and that the paper has been handled in an environmentally-friendly manner.

Australia Germany South Africa Global Service

Rossi Gearmotors Australia Pty. Ltd. Rossi GmbH Rossi Southern Africa Rossi S.p.A.
e-mail: info.australia@rossi-group.com e-mail: info.germany@rossi-group.com e-mail: info.southafrica@rossi-group.com e-mail: aftersales@rossi-group.com
www.rossi-group.com/australia www.rossi-group.com/germany www.rossi-group.com/southafrica

Benelux India Taiwan

Rossi BeNeLux B.V. Rossi Gearmotors Pvt. Ltd. Rossi Gearmotors Co. Ltd.
e-mail: info.benelux@rossi-group.com e-mail: info.india@rossi-group.com e-mail: info.taiwan@rossi-group.com
www.rossi-group.com/benelux www.rossi-group.com/india www.rossi-group.com/taiwan

Brazil Malaysia Turkey

Rossi do Brasil LTDA Rossi Gearmotors South East Asia Sdn Bhd Rossi Turkey & Middle East
e-mail: info.brazil@rossi-group.com e-mail: info.malaysia@rossi-group.com e-mail: info.turkey@rossi-group.com
www.rossi-group.com/brazil www.rossi-group.com/malaysia www.rossi-group.com/turkey

China Poland United Kingdom

Rossi Gearmotors China P.T.I. Rossi Polska Sp.z o.o. Rossi Gearmotors Ltd.
e-mail: info.china@rossi-group.com e-mail: info.poland@rossi-group.com e-mail: info.uk@rossi-group.com
www.rossi-group.com/china www.rossi-group.com/poland www.rossi-group.com/unitedkingdom

France Spain, Portugal United States, Canada, Mexico

Rossi Motorducteurs SARL Rossi Motorreductores S.L. Rossi North America

e-mail: info.france@rossi-group.com e-mail: info.spain@rossi-group.com e-mail: info.northamerica@rossi-group.com
www.rossi-group.com/france www.rossi-group.com/spain www.rossi-group.com/northamerica

Product liability, application considerations Rossi S.p.A.

The Customer is responsible for the correct selection and application of product in view of its industrial and/or commercial Via Emilia Ovest 915/A
needs, unless the use has been recommended by technical qualified personnel of Rossi, who were duly informed about 41123 Modena - Italy
customers application purposes. In this case all the necessary data required for the selection shall be communicated Phone +39 059 33 02 88
exactly and in writing by the Customer, stated in the order and confirmed by Rossi. The Customer is always responsible for fax +39 059 82 77 74
the safety of product applications. Every care has been taken in the drawing up of the catalog to ensure the accuracy of the e-mail: info@rossi-group.com
information contained in this publication, however Rossi can accept no responsibility for any errors, omissions or outdated www.rossi-group.com
data. Due to the constant evolution of the state of the art, Rossi reserves the right to make any modification whenever to Registered trademarks
this publication contents. The responsibility for the product selection is of the customer, excluding different agreements Copyright Rossi S.p.A.
duly legalized in writing and undersigned by the Parties. Subject to alterations
Printed in Italy