Fabricated & General Sprocket Data Sheet - Download it here
British Standard Cast Iron Sprocket Data Sheet - Download it here

Brooks is a world class manufacturer of large precision cut gears. We apply the same technology to our conveyor chain sprockets, which can be supplied to suit a vast array of conveyor chain types. Due to our position as a manufacturer, we are able to supply sprockets with bespoke design features, or simply replace 'like for like'.

Fabricated Conveyor Chain Sprocket
Cast Iron Conveyor Chain Sprocket

Cast iron sprockets.

We hold a wide range of cost effective cast iron sprockets for British Standard conveyor chains. We are also able to offer bespoke cast iron sprockets (pattern costs apply) and sprockets branded with our customers markings free of charge for large volume users.

We are also able to offer full machining services on all of the sprockets that we supply.

You can download our cast iron sprocket data sheet by clicking here

Fabricated sprockets to suit transmission chains up to very large pitch roller chains.

If the full chain detail is known, we are able to manufacture sprockets to suit. Due to our manufacture of large, precision cut gears, we are able to fabricate small pitch precision sprockets, right through to large heavy duty sprockets in house. With our 5 axis CNC machining centre, even the most complex sprockets can be manufactured to exacting tolerances. We take pride in our manufactured sprockets and gears, and ensure all sprockets are manufactured to the highest standard. We are able to inspect finish products with our CMM machines, with full production traceability to ISO9001:2008.

Fabricated Conveyor Chain Sprocket
Heavy Duty Conveyor Chain Sprocket

Heavy duty sprockets working under high loads or in harsh environments.

With our position as a trusted supplier to some of the world’s largest companies, we manufacture large, high breaking load conveyor chains to service conveyors in some of the toughest environments. We also supply heavy duty sprockets to suit our chains, often with bespoke tooth profiles, including large clearances and dirt relief to name a few features. By manufacturing both conveyor chain and sprockets, we are able to ensure that only the highest quality components are delivered to site, ensuring trouble free installation and the longest possible conveyor chain and sprocket life for our customers.

Split sprocket designs available with flush fitting mating faces, for ease of replacement without removing shafts. Flush fitting mating faces ensure all teeth are perfectly aligned when fitted.

Split sprockets offer similar benefits to removable tooth profiles, as they are able to be removed from the machine without removing the shaft. With a removable tooth profile, the central hub stays in position on the shaft with the chain still mounted to sprocket. With a split sprocket, the chain must be un-mounted before it can be replaced.

While it is possible to simply cut a standard sprocket in half, this leaves a gap between the mating faces, making them difficult to fit with correct clearance between each half. Brook’s split conveyor chain sprockets are fully machined with flush mating faces, ensuring correct gearing with the conveyor chain and easy assembly on site. We generally offer precision machine cut teeth, although it is possible to manufacture a split sprocket with profile cut teeth. Clamping is generally achieved by using a nut and bolt assembly or drilling and tapping the mating half of the sprocket.

For ultimate flexibility, it is possible to manufacture a split central hub with a removable tooth profile. This method of sprocket fabrication is useful when access to the head or tail shafts is particularly difficult.

Split Conveyor Chain Sprocket
Plastic Conveyor Chain Sprocket

Fully machine cut plastic sprockets available, including food grade plastics.

Plastic conveyor chain sprockets are often used in the food and waste water industries where frequent wash downs occur or where dusty/gritty operation is required, such as settlement tanks. Plastic sprockets cause less chain wear than their steel counterparts, while also offering a reduction in noise when in operation. The compressibility and deflection of plastic also helps to ensure that all of the teeth engage with the chain, spreading the load more evenly over the conveyor chain engaged with the sprocket.

Plastic conveyor chain sprockets are generally fabricated from Nylon, UHMW and Acetal, although other FDA approved materials may be used. For large diameter sprockets, it is often preferable to use a split plastic replaceable tooth ring around the outside of a central stainless steel hub. This ensures that the main body of the sprockets remains rigid, whilst still gaining the benefits that a plastic sprocket has to offer.

Fabricated replaceable teeth and large fabricated drum rings (such as trommel drives).

With our CNC milling machines we are able to produce replaceable teeth or external drum ring sprockets, which are typically used on trommel drives. Our precision engineering experience ensures that all teeth or rings are manufactured to tight tolerances if required. This is particularly important on larger trommels, to help ensure maximum tooth engagement with the chain, for an even transmission of power and a longer sprocket and chain life. We are able to supply new chain rings for conversion of trommels to a chain drive system (which does not slip when wet), or we can replace existing chain rings on a 'like for like' basis. With a wide array of machinery, materials, coatings, and heat treatments available, we can supply removable teeth and drum rings for virtually all applications.

Split Ring Conveyor Chain Sprocket
 Conveyor Chain Sprocket Special Tooth Profile

Options for special tooth profiles.

Brooks are able to offer a sprocket solution for almost any conveyor chain application. Although many sprockets are of a standard design, we are able to produce a tooth profile to suit the application. Some chains have ancillary fittings which interfere with sprocket gearing, therefore requiring a special cut away. Some conveyor chains run a mix of rollers, such as V rollers to assist with conveyor tracking. Brooks are able to manufacture sprockets with variable tooth profiles, around each sprocket to account for different roller types within a single conveyor chain assembly. We can also include greater clearances, dirt relief, modifications for flanged rollers, double pitch sprockets and many other types of specials upon request.

Optional removable/replaceable tooth profiles.

One time consuming aspect of replacing conveyor sprockets is removing the shafts from the conveyor. One option to reduce the time required is to fit a removable teeth sprocket. The most common form is to fit a ring around the outside of the hub/boss, usually split into 3 sections. On a standard conveyor, it would be possible to replace one section of teeth at a time, without having to remove the shafts or dismount the conveyor chain from the sprocket. Various types and designs of removable teeth profiles are available, depending upon the system or customer requirements.

Replaceable Teeth Conveyor Chain Sprocket
Flame Cut Conveyor Chain Sprocket

Flame cut, laser cut, water jet cut or precision machine cut profile options.

Many profiling options are available for conveyor chain sprockets, providing a variation in accuracy, but also cost. For high load precision applications, Brooks can offer a fully machine cut sprocket, produced to the same high standards as our precision cut gears. For less demanding applications where cost is critical, we are able to offer a high quality flame cut profile. In order to manufacture a cost effective yet accurate tooth form, we are also able to supply laser cut profiles for thinner materials or water jet cut on thicker materials.

Fabrication from a wide variety of materials.

As an established UK manufacturer we are able to source a wide range of high quality steels, including stainless and speciality. We are able to offer materials to suit our customer’s application, chain currently in production, or alternatively existing 'in situ' products. We can also supply full chemical & mechanical certification to EN10204 3.1B where necessary.

Conveyor Chain Sprocket Materials
Hardox Conveyor Chain Sprocket

Hardox sprockets available for the most demanding of applications.

Although Hardox is not a common material for the manufacture of sprockets, we are able to supply sprockets manufactured from Hardox when required. With a full through plate hardness of up to 60 Rockwell, Hardox can be used in high wear situations where it is preferable to wear the chain rather than the sprockets. To minimise the cost of machining time on this difficult material, it is usually preferable to fit removable Hardox toothed rings around a steel hub and backing plate.

Boss and shaft fitting options, including; weldable hubs, taper lock bushes, cone clamps, single sided/central/offset bosses, boring and keying, Gibb head keyways, bearings and counter bores etc.

There is a range of options available in order to lock sprockets on to conveyor shafts. These options include, but are not limited to, weld able hubs and taper lock bushes, cone clamps, single sided or central bosses, offset bosses, standard bore and keys with grub screws, Gibb head keyways, bearings with retaining circlips, counter bores, plain bores, splined etc.

We are able to supply 'like for like' fittings, or advise on the most suitable fitting method for the application. For a four sprocket twin strand conveyor the most typical arrangement would require 3 off sprockets with a standard bore and key, grub screws and a 1 off plain bored on to the tail shaft, to take up any variation in overall chain length (this is an example only).

Bored and Keyed Conveyor Chain Sprocket
Induction Hardened Conveyor Chain Sprocket

Flame and induction hardening services for increased sprocket life

Brook’s is able to offer hardened tooth profiles on conveyor chain sprockets for increased life over an unhardened counterpart, with application in high/heavy load or abrasive environments. Flame or induction hardening is only applied to the working tooth area, ensuring that the main body of the sprocket remains un-hardened and therefore ductile.

Flame hardening and quenching offers the most cost effective option, although case depth and achieved hardness are difficult to control. Although the achievable hardness depends upon the material, typical values are around 40-50Rc up to a depth of 3mm. Induction hardening offers a more controlled process and often achieves 55-60Rc up to 5mm in depth, depending upon the material.

Corrosion resistant coatings

Corrosion coatings are quite uncommon, due in part to the use of stainless steels for the fabrication of conveyor chain sprockets. Conveyor chain sprockets are also considered a wear part as the chain continually engages and disengages, rubbing on the faces of the sprocket and removing any coatings. Where extra protection is required, sprockets can be supplied zinc plated, galvanised, red oxide painted, or painted with other specialist corrosion resistant paints.

Coated Conveyor Chain Sprocket