An Exclusive Interview With Mr. Alessandro Zambello Managing Director Zambello Group
Zambello Gearbox Group: Expansion, Efficiency, and Sustainability
Doubling of Space and Enhanced Production Capacity with Green Solutions for a More Sustainable Future
Plants and Production of Gearboxes for Extruders
“Zambello gearboxes have become a global benchmark in the field of extruder drives,” state the company’s owners. The production is spread across two manufacturing plants, each specializing in different gearbox sizes.
Lendinara (RO) plant: Producing single- and twin-screw extruder gearboxes, with diameters ranging from 20mm to 120mm.
Magnago (MI) plant: Specialized in producing larger extruder gearboxes, with diameters from 120mm to approximately 250mm.
Thanks to continuous investments in production infrastructure, research & development, and the expansion of the commercial network, Zambello has experienced exponential growth over the past decade, culminating in a further phase of expansion for both production sites.
“We are proud to be leaders in the international market,” explain the owners, Elio and Alessandro Zambello, proudly representing the success of Made in Italy globally.
Expansion and Future Developments
The expansion of the Lendinara plant has resulted in a doubling of production space, now covering 24,000 m² of built-up area, with a total industrial land area of 154,000 m².
Given the increasing demand for large-size extruder gearboxes, a new facility and headquarters near Malpensa have been planned. This project will allow the Group to further optimize production operations while keeping the Magnago plant operational.
Innovation and Automation: The Future of Production
Over the past five years, Zambello has embraced a significant shift, incorporating automated solutions into production processes. The new Zambello 2 facility in Lendinara represents the culmination of this effort toward optimized and automated production, aimed at further enhancing efficiency.
“Our specialization and continuous commitment have earned us the trust of multinational companies in the plastic and rubber sectors,” explains Elio Zambello, “allowing us to secure important orders.”
International Recognition
Zambello’s gearbox quality has not gone unnoticed. The Group has been recognized as the “Supplier of the Year” by one of the world’s leading extruder manufacturers, Reifenhäuser, for the reliability and outstanding performance of its single- and twin-screw gearboxes.
Sustainability and Green Solutions
For years, Zambello Group has been committed to sustainability projects, focusing on innovations that reduce energy consumption. The optimization of lubrication and internal cooling has significantly reduced the amount of oil used in the gearboxes, thereby improving performance and longevity.
Downsizing projects and the introduction of robotic cleaning systems for the gearbox casings are other examples of initiatives aimed at energy savings and sustainable innovation.
Advanced Technology and Industry 4.0
At the Plast 2023 trade show, Zambello unveiled the advanced ZMS monitoring system for gearboxes, a solution designed to prevent breakdowns and minimize downtime. This system, which can be integrated within the Industry 4.0 framework, has become essential for improving production efficiency and reducing operational costs.
Through technological advancements, the Group is exploring solutions for the simultaneous control of multiple gearboxes, making the ZMS system a key component in managing complex installations.
Toward a Sustainable Future
Zambello is committed to continuously improving the performance of its gearboxes while reducing energy consumption and environmental impact. The company firmly believes that technological innovation and sustainability are crucial to continued growth in the global market.
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