CASE STUDY:  

Precision Drop-In Replacement

When the original manufacturer failed, SEW-EURODRIVE “dropped in” to save the day.

When a critical wastewater aerator drive failed, and the OEM quoted a 24-week delay, SEW-EURODRIVE engineered and delivered a custom drop-in replacement in just 14 weeks—preventing regulatory risk, costly downtime, and structural rework. Precision 3D scanning, U.S.-based assembly, and full-scope support made it a turnkey solution that saved time, money, and public trust.

Challenge:

24-Week Lead Time

When a critical aerator gear unit failed, Orange County Utilities faced a 24-week lead time from the original equipment manufacturer—completely unacceptable for one of the region’s most vital wastewater treatment processes.

Without a functioning aerator, biological treatment halts, water quality plummets, and regulatory violations loom. Making matters worse, no dimensional drawings existed for the original gearbox or coupling.

With public health on the line, the utility needed a reliable solution—and fast.

“SEW didn’t just deliver a gearbox. They delivered a complete, engineered solution—faster, more efficient, and easier to install. We were back online the same day it was delivered.”
— Lead Maintenance Supervisor, Orange County Utilities

 

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BEFORE: Failed Competitive Drive
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AFTER: SEW Drop-in Replacement

Solution:

3D Scanning + Rapid Engineering + U.S.-Assembled Heavy Industry Gear Unit

SEW-EURODRIVE stepped in with an accelerated solution: A gear unit built at its U.S. Heavy Industry Gearing Assembly Center, reducing lead time to just 14 weeks. SEW’s engineering team performed an on-site 3D scan and precision measurement to reverse-engineer the original system. This enabled them to:

  • Design a custom baseplate that matched the existing foundation
  • Engineer a custom low-speed coupling half
  • Deliver a complete drop-in replacement—no field modifications required
  • After delivery, the entire system was operational in under one day.

“This was a textbook SEW solution—reverse-engineered, locally assembled, and fully supported from design to commissioning. We delivered a high-performance drop-in replacement in record time, with zero structural changes.”
— Jason Hahn, Application Engineer, SEW-EURODRIVE USA

 

SEW-EURODRIVE Advantage:

Custom-Built, Field-Tested, Deadline-Proven: SEW-EURODRIVE Was the Right Partner.

  • Delivered 10 weeks faster than the OEM's timeline

  • Installation-ready with zero structural changes

  • Reduced the total cost of ownership with improved efficiency

  • Seamless customer experience through full-scope engineering support

Application Summary:

  • Wastewater Aerator Drive
  • Parallel shaft mixer gearbox - X3FS200/HU/B
    • 448 HP rating
    • 32.13 Ratio
    • 37 RPM output speed
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CUSTOMER:

Orange County (FL) Utilities

INDUSTRY:

Wastewater Treatment

APPLICATION:

Aerator Drive

PREVIOUS TECHNOLOGY:

Failed Gear Unit

SOLUTION:

Custom-Built Parallel-Shaft
    Mixer Gear Unit
    X3FS200 / HU / B

Image Gallery:

About SEW-EURODRIVE

Founded in 1931 in Bruchsal, Germany, SEW-EURODRIVE is a global leader in Industrial Automation, with operations in over 50 countries, 17 manufacturing plants, 92 assembly facilities, and more than 21,000 employees. The company holds over 1,000 patents, continuously driving technological advancements in gearmotors, frequency inverters, servo drives, and Industry 4.0 solutions.

SEW-EURODRIVE provides engineered solutions in countless industries, including automotive, food & beverage, pharmaceuticals, mining, steel, logistics, energy, and more, providing customized automation solutions that enhance efficiency, productivity, and sustainability. Despite its global reach, SEW remains family-owned, ensuring long-term vision, strong values, and a commitment to excellence.

SEW-EURODRIVE. Driving the World™

SEW-EURODRIVE, Inc.
220 Finch Road
Wellford, SC 29385
(P): (864) 439-7537
cslyman@seweurodrive.com
www.seweurodrive.com 

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