Quarries, pits, and plants operate around the clock, moving thousands of tons of material per shift. Crushers grind boulders into gravel. Conveyors stretch for miles, carrying rock and sand through abrasive dust clouds. Rotary kilns and dryers spin continuously in heat and grit. Tracked machines push, dig, and haul across unforgiving terrain.
Every one of these operations depends on large gears and sprockets that must endure relentless wear, shock, and corrosion. When these components fail, production stops, often at a cost of thousands of dollars per hour. Cogmatic builds the heavy-duty sprockets, gears, and rings that drive rotary motion in our best-in-class OEM customers’ equipment, keeping mining and aggregate handling operations running.
Equipment Downtime is Not an Option
At sunrise, a quarry hums with activity. Conveyors thunder as they haul crushed rock from the primary crusher to sorting screens. Trucks queue for loading, and maintenance crews monitor equipment between shifts. Then, without warning, a critical conveyor drive sprocket fails. The chain slackens, the belt stops, and the entire production line grinds to a halt.
Crews scramble to find a replacement. But the original supplier’s lead time for a replacement is months, and the only off-the-shelf options aren’t built to withstand the extreme torque and abrasion. An event that could have been avoided altogether, has now becomes weeks of lost output and missed deadlines.
Now envision that same quarry equipped with Cogmatic sprockets and gears, integrated into top-of-the-line OEM equipment. Every tooth is flame-machined in a single pass for consistent spacing. Every profile is induction-hardened, making them unaffected by grit, shock, and corrosive slurry. In the rare case they’re needed, replacement parts are designed in split-ring sections that bolt together quickly without removing the chain or track, allowing maintenance crews to restore production in a single shift.
This story repeats across the industry. A bucket elevator has been running in a limestone quarry for over 20 years with the same head and foot sprockets. A custom sprocket with 63 Rockwell flanks drives an engineered chain in an apron feeder. An 18-foot diameter, 3-inch-thick gear driven by a hydraulic motor creates the torque needed to pulverize boulders in a cone crusher.
For operators who know that downtime is the enemy, Cogmatic is the partner that delivers uptime, durability, and confidence.
Product Portfolio for Mining & Aggregates
1. Roller Chain Sprockets
Built for conveyors, feeders, and elevators. Sizes from RC-80 to RC-240, with split-ring options for quick maintenance.
2. Engineered Chain Sprockets
Heavy-duty solutions for apron feeders, dredges, and high-load conveyors. Face widths up to six inches.
3. Large Diameter Gears
Drive gears up to 18 feet, used in crushers, kilns, and mills.
4. Custom Crawler Sprockets
For tracked dozers, shovels, and trenchers. Self-cleaning and induction hardened.
5. Split Sprockets & Segments
Designed for quick field installation, minimizing downtime.
6. Gear Racks
For converting rotary motion to linear in specialized mining equipment.
7. Drum Segments & Guide Rings
Rolled and machined for rotary kilns, dryers, and trommels.
Core Mining & Aggregates Applications
Conveying & Material Handling
Conveyors are the arteries of mining and aggregate sites. From overland belts stretching across quarries to apron feeders loading crushers, these systems depend on large sprockets and chains that endure continuous loads.
Cogmatic manufactures roller chain sprockets and engineered chain sprockets for conveyors of all sizes. Our induction-hardened teeth resist the grinding abrasion of dust and stone. Flame-machined profiles maintain precise pitch, ensuring chains engage smoothly without whipping or slipping. For quick maintenance, split designs let crews replace only the worn segments, saving time and cost.
Rock Crushing
Crushers punish every component in the machine with massive torque spikes, nonstop impact, and vibration. Drive gears must transmit massive rotary power in conditions full of dust and vibration.
Cogmatic produces large-diameter gears with mating pinions built for crushers and massive sprockets for feeders. By combining high-grade U.S. steel with in-house induction hardening, we deliver components that resist cracking, peening, and tooth wear. Our flame-machined profiles guarantee exact tooth spacing, reducing the risk of uneven loading that leads to premature failure. Whether it’s an impact crusher, gyratory cone crusher, or chain-driven feeder, Cogmatic parts are made to stand strong where others fail.
Tracked Equipment
From bulldozers clearing overburden material, to trenchers and excavators tearing through rock, tracked machinery is indispensable. But their drive sprockets endure mud, grit, and high-impact torque spikes every day.
Cogmatic builds custom crawler sprockets tough enough for this abuse. Self-cleaning notches eject packed mud, while hardened flanks prevent peening and ratcheting. For large shovels and dozers, segmented rims bolt together, simplifying installation without sacrificing accuracy. These designs keep tracks engaged and equipment moving, even in the harshest conditions.
Rotary Trommels & Screens
Rotary equipment is central to moving and processing ores, cement, and aggregates. Trommel screens separate and size aggregate through constant rotation, where precision and durability are critical.
Trommel drum drives must run concentrically, often 24/7. A single out-of-round ring can lead to a jam and halt production. Cogmatic manufactures large-diameter sprockets and guide rings that keep trommels rolling true, ensuring even wear and minimal distortion.
Cogmatic produces drum segments, guide rings, large-diameter roller sprockets, and engineered chain sprockets up to 18 feet. Our manufacturing process produces concentric rings, while induction hardening extends lifespan and ensures wear resistance. The result: drums that roll true, and gears that stay aligned, ensuring crucial mining and processing equipment remains in operation, avoiding costly downtime for mines, quarries, and processing facilities.
Dewatering & Dredging
Mines and quarries often face water management challenges. Dewatering screens, dredges, and slurry pumps all require durable rotary power transfer solutions.
Cogmatic supplies split sprockets, chain wheels, and custom drive gears for wet environments where corrosion and abrasion combine. Our induction-hardened teeth resist the erosive effects of slurry. For dredges, we manufacture large bucket elevator sprockets that maintain pitch and resist sand abrasion, ensuring reliable excavation.
Excavating & Off-Highway Equipment
Massive scrapers, loaders, and dumpers rely on oversized gearing and sprockets to move tons of material. These machines face violent shock loads on rough terrain.
Cogmatic provides engineered sprockets and large gears designed to transmit power in off-highway conditions. Our components maintain engagement under load and survive the repetitive stress that quickly wears out standard parts. For OEMs designing next-generation off-highway machinery, Cogmatic delivers customizable, scalable solutions.
Trenching & Apron Feeders
Trenching machines and apron feeders are among the harshest applications in aggregates. Heavy chains drag through soil and rock, requiring sprockets that resist constant abrasion.
Cogmatic produces engineered chain sprockets and split designs that survive these brutal environments. Our flame-machined tooth forms hold pitch under load, while split sections simplify field replacement. This is critical for equipment that must run continuously in tight project timelines.
Sand-to-Oil & Specialized Processing
In sand-to-oil and other specialized processes, equipment faces unique challenges: extreme abrasives, temperature cycles, or chemical attack.
Cogmatic’s custom engineering and reverse-engineering services provide tailored solutions. Whether designing a new sprocket for a specialized machine or recreating an obsolete gear, we deliver parts that combine modern durability with exact fit.
Quality Management & Traceability
Every order moves through an ISO 9001:2015-certified workflow. Manufacturing heat numbers follow each blank from receiving to final shipment; temperature sensors validate that our induction hardening process is achieving the targeted results; and Rockwell testers confirm hardness for each sprocket or gear. Inspection reports accompany the shipment, providing maintenance planners with permanent records for audits or performance tracking.
Collaboration Without Complication
Engineers responsible for mining equipment can initiate a project using a 3D model, a legacy drawing, or even a worn component removed from a decades-old machine. Cogmatic’s team evaluates manufacturability, suggests simplifications where appropriate, and supplies a clear quotation outlining material, machining, and heat-treating steps. Cogmatic collaborates with customers to develop commercial models that align with their operational needs. We can handle single-piece requirements from one order to the next, and we can establish finished goods inventory to support higher-volume, ongoing production demand.
Sustainability & Long-Term Value
Durable steel components reduce the frequency of replacements, lowering material consumption and maintenance labor costs throughout the machine’s lifetime. Split designs allow maintenance crews to change only the worn elements, eliminating the need to pull entire shafts and reducing both downtime and resource use. Because all steel is sourced domestically, transportation from mill to finished part is far shorter than multi-continent supply chains.
When Every Hour Counts, Count on Precision
Our flame-machined sprockets hold tooth spacing so true that chains ease into engagement instead of lashing and cracking, while in-house heat treatment armors every root and flank against dust, mud, and sudden torque spikes.
To keep maintenance cycles brief, we can supply our parts in split sections, complete with factory-matched marks and alignment hardware. Field mechanics can bolt a new sprocket onto the shaft during a single service window and put the line back into operation quickly. Rigorous quality checks on run-out, hardness, and bore alignment mean each new part spins true from the first revolution—and keeps turning until the last seed is planted and the final load is hauled to storage.
Ready for the Next Challenge
Whether you need a 4-piece segmented ring gear for a rock crusher field retrofit, engineer-class chain sprockets for an elevator headshaft or a legacy rinf sprocket design for an obsolete trommel, Cogmatic already has the equipment, craftsmen, and controls in place to make it happen. All manufacturing steps (flame machining, induction heat treating, welding, finish machining, and final inspection) are managed by our dedicated team, so schedules are predictable and handling risks are minimal.
Send us a drawing, a worn sample, or simply the target performance you want to reach; our engineers will review manufacturability, suggest practical design adjustments (such as split-ring orientation, hub style, or light-weighting holes), and return with a buildable plan based on nearly a century of proven knowledge and excellence in heavy power transmission manufacturing.
For legacy machinery with no drawings at all, we can capture the critical geometry and reproduce it, often with enhanced wear protection from hardening or carburizing.
Built to Keep Moving
In the mining and aggregates industry, uptime is survival. Downtime costs money, time, and opportunity. That’s why Cogmatic products are built to last.
- Flame Machining: Single-pass precision even at massive diameters.
- Induction Hardening: Tooth surfaces that outlast standard OEM parts.
- Split and Segmented Designs: Simplify field installation and speed up repairs.
- U.S.-Sourced Steel & ISO-Certified Processes: Full traceability and consistent quality.
When reliable, long-lasting products are non-negotiable, OEMs turn to Cogmatic for proven solutions built for uninterrupted operation in the most demanding of mining environments.