High power in a space-saving design
Planetary gears from Rollstar AG are used in large tunnel boring heads. (Image: Rollstar)
Whether the Paris Metro or the London Tube — when railway tunnels are drilled in the world's major cities, innovations developed in Egliswil in Aargau will always play a role: Because modular hydraulic motors and planetary gears from Rollstar AG are used in the huge tunnel drills. Since its founding in 1966, the company has been synonymous with Swiss precision, innovation and quality. Rollstar was the world's first supplier to launch hydraulic motors and planetary gears combined as hydraulic gear motors — an innovation that continues to be at the core of the company today. "Our drive solutions proved themselves across the world in the most demanding applications and continue to do so today, from tunnel boring machines through to energy technology", says Richard Lorenz, Team Leader for Office sales and distribution at Rollstar. The performance of the drives is particularly impressive: They are designed for torques from 1500 to 6.5 million Newton metres.
In global demand
Over 90% of Rollstar products are exported abroad, meaning that the Swiss family-owned company is represented in all major global markets — from Europe to North America and Asia. One key factor to this success is the modular design of the products. "Thanks to the large number of variants for the input and output side, we are able to satisfy virtually every customer requirement", explains Richard Lorenz. Special requests are processed quickly and efficiently by the in-house CAD-supported design office.
These planetary gears will be used in a bending machine. (Image: Rollstar)
The entire production process is then carried out in-house, which guarantees high flexibility and the finest quality. What's more, ample stocks ensure short delivery times: Standard Rollstar replacement parts can reach any international airport within just 72 hours.
However, it is not just the service concept that is of great importance at Rollstar — sustainability is also a high priority, which is reflected, among other things, in the exceptionally long service life of its products: "We are in regular exchange with customers who request an overhaul for gearboxes that are 30 or more years old", says Lorenz. Unique serial numbers enable Rollstar to accurately track every unit it has ever built and manufacture the required replacement parts. This sustainable service conserves resources and enables Rollstar to set itself apart from its competitors, who focus less on the replacement parts business.
Cleanliness is a must: All components are cleaned at the Egliswil site after
the production process and before being reused. (Image: BRT)
Selling based on quality over price
The uncompromising quality of Rollstar products makes them indispensable in applications where a failure can have serious consequences, such as in tunnel construction. Rollstar is a leading global supplier of products for tunnel boring machines. Because of their extremely high torque generation and space-saving design, the compact drives also deliver impressive performance in mining, the metallurgical industry, when using large bending machines and in recycling plants.
[Translate to English:] Nachhaltigkeit wird grossgeschrieben: Zerlegtes Getriebe wartet auf die Revision. (Bild: BRT)
“In our segment, we base our selling on quality and our versatile service offering, allowing us to generate the highest possible added value for our customers when it comes to our products.”
A positive corporate culture is a key requirement for quality. "That's why we value flat hierarchies and give all of our employees the opportunity to develop further. It is also possible to exchange ideas directly with the management team at any time, for instance with CEO Lukas Ziegler". The years of service performed by the staff at Rollstar prove that this is well received: Many employees have been there for decades, and one team member has remained loyal to the company for 46 years. However, it is not just a case of looking after the current professionals, but also focusing on training the next generation: For this reason, Rollstar regularly trains young professionals in construction and polymechanics, and many of them are taken on as soon as their apprenticeship is complete.
Technical expertise and human experience are combined at Rollstar. (Image: BRT)
AI on the horizon
For the future, Rollstar is focusing on automation and digitalisation: Between 2025 and 2030, the company plans to use AI (artificial intelligence) in construction and to expand contract production. This is intended to maximise efficiency and create scope for a more intensive response to individual customer requirements. In this context, listening is essential. "Listening has always been crucial for our success", emphasises Lorenz. Many customers report that they are not listened to elsewhere. "We do the opposite. We take our time and then develop individual solutions that are truly tailored to the needs of our customers". For this purpose, cooperation with suppliers such as Brütsch/Rüegger Tools will continue in the future. "The tools supplied reliably meet our high quality requirements at all times, and ordering and communication processes are simple", explains André Stauber, Head of Manufacturing at Rollstar.
If a paint coating is desired, the products are sprayed directly at the Rollstar site. (Image: BRT)