In the realm of high-precision drive systems, Zoerkler Gears GmbH & Co KG stands as a beacon of innovation, quality, and technical excellence. From its modest beginnings as a mechanical engineers’ workshop nearly 120 years ago, the company has grown into a global leader, serving the automotive and aviation industries with cutting-edge transmission technologies. Managing Director Bernhard Wagner shares insights into Zoerkler’s journey, its state-of-the-art technologies, and the company’s vision for the future.
A Legacy of Precision and Growth
Zoerkler’s story began as a small family-run workshop, producing spare parts for local machinery. Over the decades, the company specialized in gear cutting, initially focusing on construction machinery. The turning point came in 2008 with the move to a modern 8,000-square-meter production facility in Burgenland. This allowed Zoerkler to expand its operations significantly, transforming into a manufacturer of high-performance drive systems for demanding industries.
Today, Zoerkler employs 100 skilled workers, including eight apprentices and a team of 15 highly qualified design engineers. The company’s workforce embodies its commitment to nurturing talent and fostering innovation. Wagner notes, “Our team is like a well-coordinated special forces unit. Every member is highly skilled, but the true strength comes from their ability to work together seamlessly.”
Core Competencies in Precision Drive Systems
Zoerkler specializes in the design, manufacturing, and testing of drive systems that meet the most stringent requirements. These systems power high-performance vehicles in the automotive sector and are integral to helicopters and airplanes in the aviation industry. The company also serves the railway and agricultural machinery markets, but its core focus remains on delivering precision gearboxes for the most challenging applications.
Wagner explains, “Our drive systems are custom-built to meet exacting specifications. From the initial layout to the final assembly and testing, every step is handled in-house. This integrated approach ensures that our products meet the highest standards of quality and reliability.”
Zoerkler’s in-house test center is a cornerstone of its operations. Here, advanced facilities allow for comprehensive testing, including certification of helicopter gearboxes under extreme conditions. This ensures that every product is optimized for its intended application, whether in high-performance automobiles or aviation systems.
The Role of Advanced Manufacturing Technologies
Zoerkler’s commitment to excellence is evident in its investment in state-of-the-art manufacturing equipment. The company’s decision to adopt the VL 6 vertical pick-up turning machine from EMAG exemplifies this dedication. This advanced machine enables the automated production of heavier components with unparalleled accuracy and reliability, even in small production runs.
“The VL 6 allows us to achieve exceptional dimensional accuracy while maintaining flexibility for frequent workpiece changes,” says Wagner. “Its integrated hard turning and milling functions reduce cycle times and ensure precision in every component.”
Automation is another key feature of the VL 6, enabling Zoerkler to operate the machine autonomously during second and third shifts. This significantly enhances productivity without compromising quality. The integration of the VL 6 into Zoerkler’s workflow complements an impressive array of technologies, including turning, milling, grinding, and gear cutting.
Specialized Expertise in Complex Gear Technologies
Zoerkler’s capabilities extend to producing intricate gear components, including internal gears, gear rims, and bevel gears for helicopters. The company is particularly renowned for its ability to manufacture bevel gears with angles other than 90 degrees—a highly specialized skill in the aviation industry.
This expertise is supported by Zoerkler’s focus on noise, vibration, and harshness (NVH) optimization, a critical consideration for both automotive and aviation clients. With advanced test stands and precise measurement tools, the company ensures that its gearboxes meet stringent performance and comfort standards.
Quality Assurance and Documentation
In industries like aviation, where safety and reliability are paramount, Zoerkler’s comprehensive quality assurance processes set it apart. Every component undergoes rigorous testing, with all data meticulously documented for complete traceability. From raw materials to finished products, Zoerkler maintains a batch-specific history, ensuring that clients have full confidence in the integrity of their gearboxes.
“Our quality assurance system is integrated into every stage of production,” Wagner explains. “This approach not only meets regulatory requirements but also reflects our commitment to delivering excellence.”
Shaping the Future of Mobility
Zoerkler is not resting on its laurels. The company is actively investing in research and development to address emerging trends in electrification, autonomous systems, and sustainable materials. With a focus on innovation, Zoerkler aims to play a leading role in the development of next-generation drive systems for supercars, jets, and helicopters.
“Our goal is to combine cutting-edge technology with sustainable practices,” Wagner says. “We see this as both a responsibility and an opportunity to lead in an increasingly eco-conscious market.”
A Commitment to Excellence
From its origins as a family-run workshop to its position as a global leader, Zoerkler Gears GmbH & Co KG exemplifies the transformative power of precision manufacturing. With a relentless focus on quality, innovation, and customer satisfaction, the company is well-positioned to meet the challenges of a rapidly evolving industry.
