Chains and Sprockets

Chains & Sprockets FAQ

Choosing the right chains and sprockets, and keeping them in top condition, plays a large role in how efficiently your equipment runs. Our team has compiled answers to some of the most common technical questions we receive from engineers, maintenance teams, and plant operators across New Zealand.

Q. What are the signs of worn chains or sprockets?

Excessive noise, vibration, or jumping teeth often indicate elongation in the chain or wear on the sprocket teeth. Visually, look for hooked, thinned, or “shark-fin” shaped teeth and uneven wear patterns across the sprocket face.

Q. How can I measure sprocket wear?

Sprocket wear is typically checked by measuring tooth thickness, pitch diameter, root diameter and spacing against the original specification. In precision applications, a profile gauge or digital scanning tool gives an accurate read on wear and helps decide if the sprocket still needs replacing.

Q. How can I measure chain wear?

Chain wear can be carefully measured using calipers or a tape measure.  A measurement between the pin centres over 10-20 links of chain can be compared to new chain.  Precision roller chain may need replacing at 2-3% elongation, while material handing chains may extend to 6-8%.  Depending on the nature of the process the chain is operating in, it may be necessary to replace it at a certain elongation to avoid downtime or chain failure.  Regularly measuring chain elongation can help plan for this.

Q. Should I replace sprockets when installing new chains?

In most cases, yes. Installing a new chain on a worn sprocket will wear the chain out much faster and, in some cases, cause premature chain failure. Replacing both at the same time ensures optimal performance and alignment.

Q. How can I extend the lifespan of chains and sprockets?

Regular lubrication, alignment checks, and correct tensioning are key. Avoiding overloads and ensuring sprocket teeth are free from debris also reduces wear and vibration.

Q. How does load affect chain performance?

Higher loads increase tension, wear, and fatigue across both the chain and sprockets. Selecting the right chain grade, pitch, and sprocket material is critical for maintaining strength and preventing stretching, breakage, or early fatigue.

Q. What’s the difference between metal and plastic sprockets?

Metal sprockets, typically made from steel or hardened alloys, are ideal for high-load, high-temperature environments. Plastic sprockets, made from engineering polymers, offer quieter operation, reduced weight, and excellent corrosion resistance for food processing or packaging applications.

Q. Do you manufacture custom sprockets or chain wheels?

Yes. We design, machine, and fabricate sprockets from a wide range of metals and engineering plastics, including custom tooth profiles and bores, to suit virtually any industrial chain or conveying system.

Industry News

Get a closer look at the technology and expertise behind our chain and sprocket systems. These articles cover everything from selecting the right materials, product highlights, and designing custom configurations.

• Protect your product – Non-marking chains are specifically designed to protect finished timber products, glass or any other material that is easily damaged or broken.
• Roller chain installation – WHALE brand chain pullers and chain breakers make the job easy.
• Custom applications – We redesigned a head and tail chipper infeed sprocket assembly for enhanced performance.
• Superior rust protection – CAN-AM AQUA-Proof SBR roller chain is the perfect choice where corrosion resistance and high strength is needed.