Part handling and processes for heat treating large gears have created challenges for years.  Growth in Wind Energy has brought more attention to this issue in recent years.  The vast majority of installations processing such large parts utilize conventional methods via Pit Furnace systems.  Such systems have inherent limitations with respect to quench flow and part handling making true improvements in areas such as distortion control difficult due to physical limitations of such systems.  This presentation will explain alternative methods for processing such parts that allow part distortion to be minimized.  Benefits will be quantified regarding cost savings to produce such components and quality improvement of the end product.