mud agitator schottel factory

At the production sites in Dörth and Wismar, SCHOTTEL manufactures powerful propulsion and control systems for vessels and offshore applications of all types and sizes. Using innovative logistics processes, modern manufacturing technologies and efficient production systems, qualified employees set uniform standards within the manufacturing process. Both locations meet the highest standards of quality, efficiency and environmental sustainability.

SCHOTTEL Industries GmbH is an industrial holding company with activities in the areas of marine propulsion systems, gearbox technology, automation technology and renewable energies. SCHOTTEL Industries is owned by the descendants of the founder of SCHOTTEL GmbH as well as by the Norwegian company Frydenbø Group AS. The Group currently comprises six companies and a total of around 1,200* employees.

The factory was built near company headquarters at a total investment volume of EUR 45 million and over a construction period of about 2 years. It includes four production shops (up to 270 m long and 18 m high) and a three-storey building for administration, social and technical purposes – all amounting 23,000 m² of production and office space. The new site accommodates a total of 290 jobs in production and administration, including 20 apprentice positions. The factory has been designed using the latest methods and is so versatile that it can be adapted to changing requirements over the long term. With the new site, SCHOTTEL has increased its production capacity by roughly 30%.

The key aspects for the design of the new production facility were efficiency, product quality and environmental friendliness. Professor Dr.-Ing. Gerhard Jensen, CEO of the SCHOTTEL Group, explains the construction criteria: “We refer to the new factory as the most efficient Rudderpropeller factory in the world because efficiency has been achieved in every conceivable area here. It begins with the connection to the existing traffic system and continues on to well thought-out logistics. This includes a completely roofed incoming goods and shipping area and an intelligent flow of materials based on an optimum overall layout of the factory. Quality assurance is directly next to incoming goods and shipping, and the distances for employees in production and production-related areas are short – despite the large size of the factory. Further efficiency gains and flexibility are, of course, also achieved through the versatility of the new machine tools.” Beyond this, SCHOTTEL places great importance on a work environment that is healthy and motivating. “Optimum working conditions,” notes Jensen, “are provided to employees in terms of ergonomics and the illumination of the workspaces: The combination of daylight and an automatically controlled lighting system also ensures energy efficiency. Modern ventilating and venting with corresponding filtering provides safe and oxygen-rich air. In addition, the ventilation system operates with heat recovery. Even the heat of the compressors is used for the heating of paint booths and drying booths. At the same time, the energy supplied to the water in the test bed is routed through a heat pump and used for heating offices. A photovoltaic system also supplies the plant with environmentally friendly energy.”

SCHOTTEL also invested heavily in a new machinery park. Thanks to the mechanical production facility, the company is able to efficiently produce all of the essential parts of the Rudderpropeller in-house. The largest multi-axis turning/milling centre for the machining of structural support tubes (with a diameter of up to 5 metres) and gear box housings (with a machining height of 5 metres) offers a payload of 120 tonnes. As with many other machines, it is possible to equip the machine and to machine workpieces simultaneously. The cranes for lifting range from 10 to 50 tonnes are also noteworthy. They can also be retrofitted for up to 100 tonnes should this become necessary in the future.

SCHOTTEL has always stood out for its range of manufacture. The new machine tools also increase the amount of manufacturing in-house. “This safeguards our know-how while ensuring availability and consistently high quality,” says Professor Gerhard Jensen.

Besides the plant in Dörth, SCHOTTEL has further manufacturing facilities in Wismar (Germany) and Suzhou (China). They are all modern facilities and are regularly updated to the state of the art.

Added to this, the new site of the SCHOTTEL subsidiary HW Elektrotechnik – with around 4,200 square meters of shop and office space – is nearing completion. Here, amongst others, the electrical equipment for the SCHOTTEL marine propulsion systems and controllers will be manufactured in the immediate vicinity of the Dörth plant. Product quality, energy efficiency, a healthy work environment and a forward-looking design were also important guidelines here.

The headquarters of the SCHOTTEL Group will continue to be in Spay/Rhine. The company’s service division will obtain new capacity here: the former production site will be used to accommodate the service warehouse, which was previously split across different sites. There will be a larger repair area with separate mechanical production facilities. A paint shop as well as a test and development shop will also be available. With short lines of communication and efficient logistics, SCHOTTEL will thus be able to respond to customers’ wishes even more quickly in the future.

Derrick mud agitators include an explosion-proof, “C” faced motor, reduction gearbox (helical-bevel gears for horizontal agitators or all helical gears for vertical units), impeller, and shaft with assembly bushings. Motors range from 5 to 30 HP and may be supplied in several power configurations.

Attaching the motor directly to the gearbox protects correct alignment that can increase bearing life and provides 95 percent efficiency in power transfer to the impeller. Using this superior design surpasses standard worm drive gear assemblies by 30 percent, allowing Derrick agitators to do the same work at far less horsepower. By unitizing the motor and gearbox, weight and space requirements are reduced. Horsepower, mechanical configuration, impeller diameter, and shaft length are customized to tank dimensions and maximum mud weights. Available horsepower ratings* are: 5, 7.5, 10, 15, 20, 25, and 30.

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The MAX2000® Agitator features a rugged cast iron gearbox that houses helical bevel gearing. The gear sets are precisely ground to prevent all but the slightest amount of backlash in the gear sets. This feature promotes longer life by eliminating the high impact forces generated when the unit is energized at start-up. Each helical bevel gear stage is 98% efficient. A typical worm gear set is only 85% efficient, since it loses most of its efficiency through the generation of heat.

Internal gears and bearings are lubricated with mineral oil. When the ambient temperature drops below 23ºF or rises above 140ºF, a synthetic lubricant should be substituted. A unique feature of the MAX2000® Agitator is the lower bearing, which can be maintained from the top of the tank. This feature eliminates the need for in-tank inspections of the lower bearing, and also provides a barrier of grease that can be expunged out the lower seal. The lower seals are arranged to accommodate the grease pocket and make for a four-tier layer of protection for the gearing. The end result means the lower bearing stays in contact with good, uncontaminated lubricant at all times. All four of these levels must be breached prior to loss of oil in the gearbox.

On 21 November 1921, Josef Becker lays the foundation stone for the present-day company SCHOTTEL GmbH. In his home town of Niederspay, Germany, where he learned the locksmith’s trade in his father’s smithy, he sets up his own fitter’s business in an old barn at the age of 24.

On the day the company is founded, he makes another life-changing decision. In nearby Boppard, Josef Becker marries Magdalena Karbach, an innkeeper’s daughter from a neighbouring village, whose commercial skills will make a major contribution to the success of the future SCHOTTEL shipyard.

Even before going into business himself, Josef Becker trained in shipbuilding at a shipyard in Koblenz, Germany. In 1925 he is able to put this knowledge into practice: He develops an agile boat for a local baker, which soon attracts the attention of a boatman on the Rhine. The SCHOTTEL sloop success story begins.

Once the SCHOTTEL shipyard increasingly specialized in the manufacture of ship propulsion systems, the sloop division is sold to a shipyard on the Moselle in 1973. In all, more than 16,000 sloops are produced in just under 50 years. The design and features later become the model for two DIN standards.

Construction of spacious assembly halls and a slipway with an electric hoist, as well as a home for the Becker family, which now consists of five people. They move into this home in 1935. Since the new yard is located on the Schottel section of the river, Josef Becker renames his company SCHOTTEL Werft.

In 1936, the first SCHOTTEL tractor is built on the new shipyard premises. Josef Becker will manufacture around 20 tractors to order well into the early war years, each one unique, tailored to the engine currently available.

By the end of the war, only "old men, very young apprentices and three women from Spay assigned to the company were still working in the shipyard to produce simple spare parts", Josef Becker"s eldest daughter, Anne Krautkremer said, recalling the war years at the SCHOTTEL shipyard.

In the early 1950s, Josef Becker develops a self-sufficient propulsion system based on the rudder propeller, which can turn virtually any floating device into a self-propelled unit: the SCHOTTEL Navigator, which quickly becomes the second key component of the shipyard alongside the sloop.

The Navigator can be easily mounted on any marine vessel and combines all the necessary components of a propulsion system: engine, fuel tank, clutch, shaft, the SCHOTTEL RudderPropeller and all auxiliary units.

In addition to Rhine ferries, tugboats and pusher craft, the SCHOTTEL shipyard also equips crane ships, supply vessels for oil platforms, dredgers, pontoon ferries, tankers, research vessels and weather vessels as well as fishing fleets with Navigators, in Europe as well as in the Middle East, Asia and South America.

With the establishment of SCHOTTEL Nederland, SCHOTTEL lays the foundation for its internationalization. Initially, rudder propellers and Navigators are produced in The Hague for the domestic and global market, plus from 1962 onwards, the production of sloops and type boots at a shipyard purchased in Warmond is also added.

In the 1960s, the site specializes in the production of larger rudder propellers for the offshore industry, thus making a significant contribution to their worldwide distribution. In 1989, production is relocated back to Spay, and SCHOTTEL Netherlands has focused on sales and service ever since.

In order to ensure sales and customer service in North and Central America, the North American subsidiary is founded in 1961, providing crucial impetus for larger rudder propellers. Since October 2013, SCHOTTEL Inc. has operated a facility for its customers in Houma, Louisiana.

In 1963, SCHOTTEL equips the first vessel fitted with a dynamic positioning system with rudder propellers. Through the subsequent close collaboration with the offshore industry, SCHOTTEL propulsion units gradually become established in almost all offshore applications.

During the offshore boom, which will continue until 2015, SCHOTTEL is able to secure a 20 percent market share in the platform supply vessel segment. Today, offshore wind farms are a growing market in which SCHOTTEL is successfully asserting itself.

In the mid-1960s, SCHOTTEL adds transverse thrusters to its range. The auxiliary propulsion units, which provide thrust either to port or starboard, further enhance manoeuvrability and over the decades have been continuously refined in the areas of design, noise generation and installation.

These days, SCHOTTEL TransverseThrusters improve the manoeuvrability of ships in many areas of operation. In 2020, for example, a low-noise propeller design is being developed for Germany’s cutting-edge research vessel, the Atair, which will create optimum research conditions and protect the marine environment.

Together with the shipping company Ulrich Harms of Hamburg, Germany, SCHOTTEL develops the first harbour tug equipped with a rudder propeller. The JANUS, which is still in service today under the name Jan Leenheer, carries out manoeuvres with two SRP 300s, which open up completely new manoeuvring capabilities and applications for the tug.

SCHOTTEL responds to the rapid increase in performance in the tugboat market, caused by ever larger container ships, by developing increasingly more powerful propulsion units, including the SRP 1515 in 1998. It is renamed the SRP 460 in 2016 and becomes the most successful model in the company’s product history.

Despite numerous crises in the shipping industry, SCHOTTEL is continuously expanding its leading position in the tugboat market worldwide. By 2021, more than 2,000 azimuth tugs with bollard pull capacities of up to 120 tonnes will be used all over the world with SCHOTTEL propulsion units, including Europe’s first hybrid tug.

With three new subsidiaries, SCHOTTEL succeeds in expanding its international presence during the 1970s. In 1971, the SCHOTTEL France branch opens in Paris, followed by SCHOTTEL Far East in Singapore in 1972 and SCHOTTEL do Brasil in Rio de Janeiro in 1975.

When Josef Becker dies in 1973, the SCHOTTEL shipyard has a worldwide workforce of 500 people. In 2004, the developer of the RudderPropeller was posthumously presented with the Elmer A. Sperry Award for a "groundbreaking propulsion and steering system, whereby Josef Becker and his team carried out truly pioneering work for the shipping industry."

In parallel with the development of the rudder propeller, SCHOTTEL begins to develop steering systems that enable 360° deflection. 1981 sees the launch of the Master Pilot, followed by the Masterstick in 2001. The tailor-made joystick system enables up to eight propulsion units to be controlled with just one lever.

In 1986, the SRP 4500, the largest rudder propeller ever built, is installed in the crane ship MICOPERI 7000. The SRP 4500 has a propeller diameter of 4.20 metres and generates a thrust of around 80 tonnes. To this day, the MICOPERI is still in service as the SAIPEM 7000 together with its SRP 4500, which is regularly serviced by SCHOTTEL.

The SCHOTTEL shipyard has been designing and building pusher and tug boats for the German armed forces since the late 1960s. In 1987, the first M3 pioneer boats with PumpJet propulsion go into production, with a draught of just 39 centimetres. In total, almost 1000 M-boats leave the SCHOTTEL shipyard.

In 1995, SCHOTTEL establishes its sixth subsidiary in the Chinese city of Suzhou, 95 km from Shanghai. With an investment volume of six million DM (3 million euros), the Chinese production facility is built within just one year.

Due to its efficiency, the twin propeller quickly achieves a breakthrough. It is used in offshore applications, ferries and river cruise ships, where its compact design makes it the preferred propulsion system. By 2020, SCHOTTEL will equip more than 60 Viking River Cruises vessels with a twin propeller.

In 1997, Siemens and the SCHOTTEL shipyard establish the Siemens-SCHOTTEL Propulsor (SSP) consortium and develop a new type of propulsion unit, characterized by the type of electric motor used in an underwater pod. The SSP is used in the cruise ferries "Peter Pan" and "Nils Holgersson", among others.

SCHOTTEL responds to the demand for smaller pod drives from 2002 onwards with the development of the SCHOTTEL Electric Propulsor (SEP), which is available in five sizes ranging from 1 to 5 MW. Multi-purpose vessels, icebreakers, research vessels and landing platform dock vessels, among others, will be fitted with an SEP.

In 1999, SCHOTTEL takes over WPM Wismarer Propeller- und Maschinenbau GmbH in northern Germany and invests DM 30 million (15 million euros) in the construction of a new production and assembly facility. Controllable-pitch propulsion systems are manufactured in Wismar, in addition to the largest rudder propellers and all retractable propulsion systems.

The exceptionally propulsion-efficient controllable pitch propellers (SCP, SCHOTTEL ControllablePropellers) combine maximum thrust force and excellent manoeuvrability. To further increase efficiency, SCHOTTEL engineers would develop a new five-bladed hub with an optimized propeller design for fast vessels in 2012.

In 2003, SCHOTTEL presents a high-torque L-type propulsion system, whose electric motor is, in part, vertically integrated into the propulsion unit’s supporting tube. This results in an extremely compact design and low installation height – ideal for ships with limited space.

With the aim of increasing the load-bearing capacity of SCHOTTEL toothed wheels to the extent that each tooth can be subjected to 15 percent more stress, SCHOTTEL engineers develop the HTG® high-performance gearbox. This enables SCHOTTEL to design propulsion units that are more compact as well as more efficient.

In 2007, the collaboration with Frydenbø Industri AS, which has existed since 1954, is further intensified. The Norwegian company acquires 15.4% of the shares in SCHOTTEL GmbH. At the same time, a Supervisory Board is installed with Knut Herman Gjøvaag, the owner of Frydenbø Industri, as Chairman of the Supervisory Board.

In 2009, Prof. Dr.-Dipl. Gerhard Jensen becomes sole CEO, replacing the dual management team that has existed since 1999. Under his aegis, SCHOTTEL is able to more than double its turnover. This is attributable to the growing market share in the offshore sector and the expansion of the stable market leadership in harbour tugs.

Since knowledge of the condition of a vessel"s propulsion systems is essential for safe operation, SCHOTTEL launches the Condition Monitoring System (CMS) in 2011. With the aid of numerous sensors, CMS ensures preventive monitoring of all relevant propulsion components.

From 2011 onwards, SCHOTTEL presses ahead with internationalization. A total of nine new subsidiaries will be established: SCHOTTEL China (SSTS), SCHOTTEL Russia and SCHOTTEL Middle East in 2011, SCHOTTEL Australia in 2013, SCHOTTEL Canada in 2014, SCHOTTEL de Colombia in 2015, SCHOTTEL Nordic in 2016, SCHOTTEL Turkey in 2018 and SCHOTTEL Italy in 2020

In 2012, SCHOTTEL expands its product range to include an electric propulsion system without a gearbox or a drive shaft. Thanks to its design, the SRT boasts low noise and vibration levels and is used primarily in vessels carrying passengers.

Following a construction period of around two years, the new production site in Dörth in the Hunsrück region is completed in 2015. An investment of 45 million euros has created an ultra-modern rudder propeller factory, enabling SCHOTTEL to manufacture on premises that are optimally adapted to the production processes for the very first time.

From the RudderPropeller, PumpJet and TwinPropeller through to the EcoPeller: Time and again, SCHOTTEL provides the solution to the latest requirements in the ferry industry. This has enabled the company to become the propulsion expert for "floating bridges" and is now the world leader in double-ended ferries.

To enable optimized ship operation, SCHOTTEL 2020 develops a modular software system into which numerous automation solutions for monitoring can be integrated. This is complemented by the data acquisition and transmission system MariHub and the IoT analysis platform MariNet.

SCHOTTEL Italia opens on 1 October 2020 as the youngest member of the global SCHOTTEL family. The Bolzano-based subsidiary focuses on the prospering sub-segments of mega-yachts and passenger shipping in southern Europe, where SCHOTTEL has been operating successfully for more than 60 years.

Founded in 1921 by Josef Becker, SCHOTTEL GmbH celebrates its centenary in 2021. 100 years of SCHOTTEL – also 100 years of economic and shipping history, which SCHOTTEL has played a major part in shaping thanks to its invention of the RudderPropeller and its innovative advancements.

The targeted expansion of SCHOTTEL"s international network of subsidiaries developed further with the foundation of SCHOTTEL East Asia. In addition to the growing market in South Korea, business development of the German propulsion expert will now also be intensified in Japan.