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Moves to AC Technology with Help from Baldor

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solutions
A Publication Featuring Baldor Electric Company Products
Number 9
magazine
Domtar's
Marlboro
Paper Mill
P.O. Box 2400, Fort Smith, AR 72902-2400 USA, Ph: (1) 479.646.4711, Fax: (1) 479.648.5792, International Fax: (1) 479.648.5895
baldor.com
©2012 Baldor Electric Company
Solutions0812
All Rights Reserved. Printed in USA.
X/XX-XX-13M
Pl u s
Moves to
AC Technology
with Help from Baldor
Baldor•Reliance® Large AC Motors
Installed Ten Years Ago at Holcim’s Holly Hill Plant
Continue to Provide Reliable Service
Malteurop North America
Selects Reliable Baldor Products for Malthouse Upgrade
The First Name in
Power Transmission
Cover: PG 16
Contents
Solutions Magazine
Number 9
Featuring Baldor•Reliance® & Baldor•Dodge® Products
baldor.com
2 Briefings
4 Baldor•Reliance® Large AC Motors
Installed Ten Years Ago at Holcim's Holly Hill Plant Continue to Provide
Reliable Performance
10 Ten-Year Partnership
Between Concept Machine & Design and Baldor is Labeled a Success
16 Domtar's Marlboro Paper Mill Moves
to AC Technology with Help from Baldor
Baldor•Dodge® power transmission products offer
reliable service and low maintenance to help reduce
your total cost of ownership. Our innovative bearings,
gearing and power transmission products have
solved the toughest applications for over 125 years.
Our technical sales team can help you with the
most challenging applications, and our worldwide
distributor network ensures immediate delivery.
• Unmatched Quality
22 Malteurop North America Selects
Reliable Baldor Products for Malthouse Upgrade
• Superior Reliability
28 Baldor's Dodge® MagnaGear™ In-Stock Program
Gets Barge Conveyor Back Up and Running
• Improved Uptime
When it comes to PT solutions, Baldor•Dodge is the
first name in power transmission.
baldor.com
479-646-4711
• Quick Delivery
Baldor’s mission is to be the best (as determined by our
customers) marketers, designers and manufacturers
of industrial electric motors, mechanical power
transmission products, drives and generators.
Solutions Magazine is published by the Marketing Communications Department of Baldor Electric Company.
For more information, please email [email protected]
baldor.com
The First Name in
Power Transmission
Cover: PG 16
Contents
Solutions Magazine
Number 9
Featuring Baldor•Reliance® & Baldor•Dodge® Products
baldor.com
2 Briefings
4 Baldor•Reliance® Large AC Motors
Installed Ten Years Ago at Holcim's Holly Hill Plant Continue to Provide
Reliable Performance
10 Ten-Year Partnership
Between Concept Machine & Design and Baldor is Labeled a Success
16 Domtar's Marlboro Paper Mill Moves
to AC Technology with Help from Baldor
Baldor•Dodge® power transmission products offer
reliable service and low maintenance to help reduce
your total cost of ownership. Our innovative bearings,
gearing and power transmission products have
solved the toughest applications for over 125 years.
Our technical sales team can help you with the
most challenging applications, and our worldwide
distributor network ensures immediate delivery.
• Unmatched Quality
22 Malteurop North America Selects
Reliable Baldor Products for Malthouse Upgrade
• Superior Reliability
28 Baldor's Dodge® MagnaGear™ In-Stock Program
Gets Barge Conveyor Back Up and Running
• Improved Uptime
When it comes to PT solutions, Baldor•Dodge is the
first name in power transmission.
baldor.com
479-646-4711
• Quick Delivery
Baldor’s mission is to be the best (as determined by our
customers) marketers, designers and manufacturers
of industrial electric motors, mechanical power
transmission products, drives and generators.
Solutions Magazine is published by the Marketing Communications Department of Baldor Electric Company.
For more information, please email [email protected]
baldor.com
B r ie f in g s
B r ie f in g s
Baldor Now Offers Complete Line
of Large AC Motors
Baldor's New Dodge® Disc Coupling Engineered for the Oil and Gas Industry –
Offering Improved Reliability, Increased Productivity and Lower Costs
Baldor now offers customers in North
America access to the most complete
line of large AC motors in the world
from a single, local sales team.
The new Dodge Disc coupling, designed
to meet the American Petroleum
Institute (API) 610 specification, is the
ideal solution for pumping applications
in the oil and gas industry.
Baldor•Reliance® stock and custom
motors are available up to 15,000 HP,
while ABB induction and synchronous
motors are available up to 100,000 HP.
This large AC motor offering includes
both NEMA and IEC configurations,
assuring customers that they will get
the motor that meets frame, enclosure
and duty cycle standards for any
application, anywhere in the world.
Every large AC motor is designed and
built for superior reliability, energy
savings and rugged performance.
The Dodge Disc coupling utilizes the
newest generation of disc geometry,
which minimizes disc stress during
operation, and produces the highest
misalignment and torque capability
of any disc coupling on the market.
(See details below.) These capabilities
improve reliability and extend the
overall life of the coupling.
This new coupling also allows users
to lower costs by offering a large
hub option that increases the max
bore capability in applications where
the coupling size is driven by the
shaft diameter instead of the torque
requirement.
Local presence, combined with a global
technical field sales support team
serving both Baldor and ABB, means
customers will receive the best service
and support in the industry.
Additionally, the Dodge Disc coupling
offers all the advantages of a metallic
coupling, including a large bore
Baldor's Dodge® PTplace.com Goes Mobile
There’s a new mobile website for
PTplace.com users that provides realtime, online inventory availability of
Dodge power transmission products
from a mobile device.
phone calls and emails. Today, with the
new PTplace Mobile site, they have
a quick and convenient way to access
product details and check stock and
pricing.
PTplace Mobile is easy to use and
allows users to get detailed part
information and pricing using the same
log-in credentials as PTplace.com. A
functionality called "Super search" also
enables searching by description or
partial part numbers.
The mobile site can be accessed by
typing m.ptplace.com into the browser
of any mobile device.
range, high speed capabilities,
high torque ratings and precision
balancing. However, because the
Dodge product does not have relative
movement between mating surfaces,
there is no need for lubrication,
resulting in reduced maintenance and
increased productivity.
ABB and Baldor•Reliance® motors are
recognized by the oil and gas industry
as industry-leading
products, offering
superior performance and
reliability. Now these users can get the
same level of quality from an entire
pump driver package by incorporating
the Dodge Disc coupling into all
pumping applications.
Dodge Disc Geometry Makes The Difference
While competitors utilize a disc geometry that features a single scalloped design, the new Dodge Disc coupling utilizes the
newest generation of disc geometry – a dual scalloped design. This new design offers an even distribution of material along the
“axis of bolt center,” which drastically reduces the number of high stress areas within the disc. The peak stress in the Dodge
Disc geometry is 13% less than the competitor’s geometry, resulting in an average of double the torque capacity. Additionally,
an even distribution of material along the “axis of bolt center” maximizes misalignment capability and offers up to three times
the misalignment of the leading competitor. Industry-leading torque ratings and misalignment capability will ultimately lead to
longer coupling life and improved reliability.
PTplace.com is operated by CoLinx, LLC,
an e-commerce and logistics service provider
owned by five manufacturers.
Currently the PTplace.com website
serves over 20,000 distributor
employees who track inventory
and place orders more than 65,000
times a day. In the past, outside sales
representatives retrieved critical
information by relying on catalogs,
2 | Solutions Magazine | Number 9
Number 9 | Solutions Magazine | 3
B r ie f in g s
B r ie f in g s
Baldor Now Offers Complete Line
of Large AC Motors
Baldor's New Dodge® Disc Coupling Engineered for the Oil and Gas Industry –
Offering Improved Reliability, Increased Productivity and Lower Costs
Baldor now offers customers in North
America access to the most complete
line of large AC motors in the world
from a single, local sales team.
The new Dodge Disc coupling, designed
to meet the American Petroleum
Institute (API) 610 specification, is the
ideal solution for pumping applications
in the oil and gas industry.
Baldor•Reliance® stock and custom
motors are available up to 15,000 HP,
while ABB induction and synchronous
motors are available up to 100,000 HP.
This large AC motor offering includes
both NEMA and IEC configurations,
assuring customers that they will get
the motor that meets frame, enclosure
and duty cycle standards for any
application, anywhere in the world.
Every large AC motor is designed and
built for superior reliability, energy
savings and rugged performance.
The Dodge Disc coupling utilizes the
newest generation of disc geometry,
which minimizes disc stress during
operation, and produces the highest
misalignment and torque capability
of any disc coupling on the market.
(See details below.) These capabilities
improve reliability and extend the
overall life of the coupling.
This new coupling also allows users
to lower costs by offering a large
hub option that increases the max
bore capability in applications where
the coupling size is driven by the
shaft diameter instead of the torque
requirement.
Local presence, combined with a global
technical field sales support team
serving both Baldor and ABB, means
customers will receive the best service
and support in the industry.
Additionally, the Dodge Disc coupling
offers all the advantages of a metallic
coupling, including a large bore
Baldor's Dodge® PTplace.com Goes Mobile
There’s a new mobile website for
PTplace.com users that provides realtime, online inventory availability of
Dodge power transmission products
from a mobile device.
phone calls and emails. Today, with the
new PTplace Mobile site, they have
a quick and convenient way to access
product details and check stock and
pricing.
PTplace Mobile is easy to use and
allows users to get detailed part
information and pricing using the same
log-in credentials as PTplace.com. A
functionality called "Super search" also
enables searching by description or
partial part numbers.
The mobile site can be accessed by
typing m.ptplace.com into the browser
of any mobile device.
range, high speed capabilities,
high torque ratings and precision
balancing. However, because the
Dodge product does not have relative
movement between mating surfaces,
there is no need for lubrication,
resulting in reduced maintenance and
increased productivity.
ABB and Baldor•Reliance® motors are
recognized by the oil and gas industry
as industry-leading
products, offering
superior performance and
reliability. Now these users can get the
same level of quality from an entire
pump driver package by incorporating
the Dodge Disc coupling into all
pumping applications.
Dodge Disc Geometry Makes The Difference
While competitors utilize a disc geometry that features a single scalloped design, the new Dodge Disc coupling utilizes the
newest generation of disc geometry – a dual scalloped design. This new design offers an even distribution of material along the
“axis of bolt center,” which drastically reduces the number of high stress areas within the disc. The peak stress in the Dodge
Disc geometry is 13% less than the competitor’s geometry, resulting in an average of double the torque capacity. Additionally,
an even distribution of material along the “axis of bolt center” maximizes misalignment capability and offers up to three times
the misalignment of the leading competitor. Industry-leading torque ratings and misalignment capability will ultimately lead to
longer coupling life and improved reliability.
PTplace.com is operated by CoLinx, LLC,
an e-commerce and logistics service provider
owned by five manufacturers.
Currently the PTplace.com website
serves over 20,000 distributor
employees who track inventory
and place orders more than 65,000
times a day. In the past, outside sales
representatives retrieved critical
information by relying on catalogs,
2 | Solutions Magazine | Number 9
Number 9 | Solutions Magazine | 3
B r ie f in g s
B r ie f in g s
Baldor•Reliance
Large AC Motors
Installed Ten Years Ago
®
at Holcim's Holly Hill Plant
Continue to Provide
Reliable Performance
4 | Solutions Magazine | Number 9
Number 9 | Solutions Magazine | 5
B r ie f in g s
B r ie f in g s
Baldor•Reliance
Large AC Motors
Installed Ten Years Ago
®
at Holcim's Holly Hill Plant
Continue to Provide
Reliable Performance
4 | Solutions Magazine | Number 9
Number 9 | Solutions Magazine | 5
f e at u r e s
F e at u r e s
Both Allen Davis and David Berry,
electrical instrumentation technicians,
worked at the old plant and helped
commission the new facility. Davis says
maintenance costs were high at the
old plant because of constantly failing
motors. But over the past 10 years,
that hasn’t been the case because the
Baldor•Reliance motors have been
reliable.
“We routinely test our large AC
motors, and I’ve been impressed with
the results,” says Davis. “When we
meg these motors, we see very high
resistance, which is good because we
know we don’t have to worry about the
motors shorting out. I’m very pleased
with these motors because they just run
and run, and we sleep better knowing
these motors test well.”
An 800 HP Baldor•Reliance TEFC (blower assist cooled) motor is used on the coal mill drive that grinds
the coal used to fire the kiln.
Holcim (US) Inc. is a subsidiary of
Holcim Ltd and one of the nation’s
leading manufacturers and suppliers
of cement. The company operates 12
manufacturing plants in the United
States, including the facility in Holly
Hill, South Carolina.
Cement has been produced at this
location since 1966, but a little over
10 years ago, work began to construct a
new energy-efficient plant on the Holly
Hill site.
In addition to increasing the plant’s
overall efficiency, the company built
the new plant with reliability in mind
in order to reduce maintenance costs.
The new mill is twice the size of the old
facility with a capacity of 2.2 million
metric tons per year.
Because large AC motors are used in
the most critical applications, company
officials chose to install Baldor•Reliance
large AC motors. After more than
nine years in operation, the team that’s
responsible for keeping the plant up
and running says the company made the
right choice.
This 2,700 HP WPII Baldor•Reliance motor operates the main bag house dust collector. The captured particulates are recycled back into the cement-making
process.
6 | Solutions Magazine | Number 9
The dilution air fan is powered by a 700 HP WPII Baldor•Reliance motor. This fan pulls heat from the
clinker cooler to help dry raw materials in the raw mill using the hot gas generator.
Number 9 | Solutions Magazine | 7
f e at u r e s
F e at u r e s
Both Allen Davis and David Berry,
electrical instrumentation technicians,
worked at the old plant and helped
commission the new facility. Davis says
maintenance costs were high at the
old plant because of constantly failing
motors. But over the past 10 years,
that hasn’t been the case because the
Baldor•Reliance motors have been
reliable.
“We routinely test our large AC
motors, and I’ve been impressed with
the results,” says Davis. “When we
meg these motors, we see very high
resistance, which is good because we
know we don’t have to worry about the
motors shorting out. I’m very pleased
with these motors because they just run
and run, and we sleep better knowing
these motors test well.”
An 800 HP Baldor•Reliance TEFC (blower assist cooled) motor is used on the coal mill drive that grinds
the coal used to fire the kiln.
Holcim (US) Inc. is a subsidiary of
Holcim Ltd and one of the nation’s
leading manufacturers and suppliers
of cement. The company operates 12
manufacturing plants in the United
States, including the facility in Holly
Hill, South Carolina.
Cement has been produced at this
location since 1966, but a little over
10 years ago, work began to construct a
new energy-efficient plant on the Holly
Hill site.
In addition to increasing the plant’s
overall efficiency, the company built
the new plant with reliability in mind
in order to reduce maintenance costs.
The new mill is twice the size of the old
facility with a capacity of 2.2 million
metric tons per year.
Because large AC motors are used in
the most critical applications, company
officials chose to install Baldor•Reliance
large AC motors. After more than
nine years in operation, the team that’s
responsible for keeping the plant up
and running says the company made the
right choice.
This 2,700 HP WPII Baldor•Reliance motor operates the main bag house dust collector. The captured particulates are recycled back into the cement-making
process.
6 | Solutions Magazine | Number 9
The dilution air fan is powered by a 700 HP WPII Baldor•Reliance motor. This fan pulls heat from the
clinker cooler to help dry raw materials in the raw mill using the hot gas generator.
Number 9 | Solutions Magazine | 7
F e at u r e s
F e at u r e s
Another aspect of their motor
preventive-maintenance program is
vibration analysis. Berry says monitoring
and trending vibration helps identify
potential problems, particularly with
the rotor or stator, so corrective actions
can be taken before failure. Considered
a key indicator of health, the tests show
the large AC motors throughout the
plant are running well.
“Because vibration can tell you so much,
we have brought in an outside third
party to conduct on-line testing,” says
Berry. “We have not seen any issues that
would lead us to believe any of these
motors need anything other than routine
attention. I can’t think of anything that
we have uncovered by doing this testing
– and that’s a good thing.”
Baldor•Dodge Sleevoil RTL
hydrodynamic bearings can be found
on fan applications throughout the
Holly Hill plant. This bearing is an
ideal choice because the liner design
offers excellent radial and thrust load
capacities and exceptional bearing
life with minimal maintenance.
This standard water-cooled unit is
premachined for thermocouples, a
vibration sensor, circulating oil and
auxiliary seals to allow for monitoring
and extra protection. Plant reliability
engineer Enrique Reyes says that
there have never been any issues with
these bearings and that they only
require maintenance once per year to
drain and replace a small amount of
oil. He says he doesn’t really worry
about these bearings because they
have never caused him any problems.
®
“These motors are so dependable the repair people
no longer get any work from us, and that’s
a very good thing.”
For Davis, it’s also clear the right motor
selection was made and credits its
performance to quality windings and
superior insulation systems. Davis says
he and Berry remember the old days
when they chased motors to keep the
plant running, but he’s happy to report
that those days are long gone.
“There was a time when motor repair
people lived at our plant,” says Davis.
“A motor shop guy still stops by each
week asking if we have any motors to
be repaired, and it’s a blessing for me
to tell him no. These motors are so
dependable the repair people no longer
get any work from us, and that’s a very
good thing.”
Allen Davis,
electrical instrumentation technician,
Holcim Holly Hill plant
®
8 | Solutions Magazine | Number 9
The kiln-induced draft (ID) fan is powered by a 5,000 HP WPII Baldor•Reliance large AC motor. The
ID fan is a central element in the clinker production process as raw meal is fed into the kiln and sintered.
Throughout the facility you’ll find
Baldor•Reliance large AC motors,
ranging from 400 HP all the way to
5,000 HP, running critical applications.
Because the plant is not designed
for backup, losing any one of these
motors would be catastrophic. But
after more than nine years of troublefree performance, Berry believes these
motors are built to last.
“It may be hard to believe, but we
haven’t had any problems with our
large AC motors,” says Berry. “I know
a lot of thought went into the selection
of motors for our new plant, and today
we can say they chose a good product.
These big motors are very reliable, and
by maintaining them the way we do,
they will last for a very long time.”
A Baldor•Reliance 1,200 HP WPII (blower assist cooled) motor rotates the kiln about one to three revolutions per minute. Raw meal in the kiln is heated to
about 2,700 F to produce clinker, which is then cooled and ground into the gray powder known as Portland Cement.
Number 9 | Solutions Magazine | 9
F e at u r e s
F e at u r e s
Another aspect of their motor
preventive-maintenance program is
vibration analysis. Berry says monitoring
and trending vibration helps identify
potential problems, particularly with
the rotor or stator, so corrective actions
can be taken before failure. Considered
a key indicator of health, the tests show
the large AC motors throughout the
plant are running well.
“Because vibration can tell you so much,
we have brought in an outside third
party to conduct on-line testing,” says
Berry. “We have not seen any issues that
would lead us to believe any of these
motors need anything other than routine
attention. I can’t think of anything that
we have uncovered by doing this testing
– and that’s a good thing.”
Baldor•Dodge Sleevoil RTL
hydrodynamic bearings can be found
on fan applications throughout the
Holly Hill plant. This bearing is an
ideal choice because the liner design
offers excellent radial and thrust load
capacities and exceptional bearing
life with minimal maintenance.
This standard water-cooled unit is
premachined for thermocouples, a
vibration sensor, circulating oil and
auxiliary seals to allow for monitoring
and extra protection. Plant reliability
engineer Enrique Reyes says that
there have never been any issues with
these bearings and that they only
require maintenance once per year to
drain and replace a small amount of
oil. He says he doesn’t really worry
about these bearings because they
have never caused him any problems.
®
“These motors are so dependable the repair people
no longer get any work from us, and that’s
a very good thing.”
For Davis, it’s also clear the right motor
selection was made and credits its
performance to quality windings and
superior insulation systems. Davis says
he and Berry remember the old days
when they chased motors to keep the
plant running, but he’s happy to report
that those days are long gone.
“There was a time when motor repair
people lived at our plant,” says Davis.
“A motor shop guy still stops by each
week asking if we have any motors to
be repaired, and it’s a blessing for me
to tell him no. These motors are so
dependable the repair people no longer
get any work from us, and that’s a very
good thing.”
Allen Davis,
electrical instrumentation technician,
Holcim Holly Hill plant
®
8 | Solutions Magazine | Number 9
The kiln-induced draft (ID) fan is powered by a 5,000 HP WPII Baldor•Reliance large AC motor. The
ID fan is a central element in the clinker production process as raw meal is fed into the kiln and sintered.
Throughout the facility you’ll find
Baldor•Reliance large AC motors,
ranging from 400 HP all the way to
5,000 HP, running critical applications.
Because the plant is not designed
for backup, losing any one of these
motors would be catastrophic. But
after more than nine years of troublefree performance, Berry believes these
motors are built to last.
“It may be hard to believe, but we
haven’t had any problems with our
large AC motors,” says Berry. “I know
a lot of thought went into the selection
of motors for our new plant, and today
we can say they chose a good product.
These big motors are very reliable, and
by maintaining them the way we do,
they will last for a very long time.”
A Baldor•Reliance 1,200 HP WPII (blower assist cooled) motor rotates the kiln about one to three revolutions per minute. Raw meal in the kiln is heated to
about 2,700 F to produce clinker, which is then cooled and ground into the gray powder known as Portland Cement.
Number 9 | Solutions Magazine | 9
F e at u r e s
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i
h
s
r
e
n
t
r
a
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r
a
e
Y
Ten
s
s
e
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a
L
10 | Solutions Magazine | Number 9
F e at u r e s
N
ot only does James Turner build his own
labeling equipment for his family-owned
business that specializes in heat-transfer
decoration, but he also founded a separate
company – Concept Machine & Design –
that custom designs and manufactures heat transfer
labeling equipment for the packaging industry.
Whether it’s providing labeling services or providing
innovative equipment, Turner’s businesses are known
for quality. And he credits a portion of his success to
his 10-year partnership with Baldor.
Number 9 | Solutions Magazine | 11
F e at u r e s
p
i
h
s
r
e
n
t
r
a
P
r
a
e
Y
Ten
s
s
e
c
c
u
S
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b
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10 | Solutions Magazine | Number 9
F e at u r e s
N
ot only does James Turner build his own
labeling equipment for his family-owned
business that specializes in heat-transfer
decoration, but he also founded a separate
company – Concept Machine & Design –
that custom designs and manufactures heat transfer
labeling equipment for the packaging industry.
Whether it’s providing labeling services or providing
innovative equipment, Turner’s businesses are known
for quality. And he credits a portion of his success to
his 10-year partnership with Baldor.
Number 9 | Solutions Magazine | 11
F e at u r e s
F e at u r e s
That’s why when his company, based
in Burlington, Kentucky, was awarded
the contract to build 15 heat transfer
labeling machines for a large food
manufacturer, there was no doubt that
Baldor motion control products would
be used on these machines.
System integrator Steve Ziegler, with
Zigtronics Inc., also has a long history
working with Turner, Baldor and the
Cincinnati district office. He was a part
of this latest project from the beginning
and says the machine the team
designed is a very sophisticated piece
of equipment that uses a heat-transfer
process that labels three panels of a
round container in one motion, instead
of doing each panel individually.
“The container is moved into a nesting
nozzle that grabs the container and
indexes it to a specific mark putting
the container into position,” explains
Ziegler. “Next the label is applied using
a heat process to apply the label on in a
3% stretch onto the container before it
exits the machine. The label placement
has to be plus or minus 1/32" at the
part seam, and we rely on the Baldor
equipment to maintain this position
accuracy.”
The Baldor products selected to make
sure that the motion, position and
pressure are right every time include
the NextMove® e100 motion controller,
seven MicroFlex® e100s and seven servo
motors. Ziegler says because the motion
controller is an Ethernet Powerlink
integrated hub, it communicates to each
individual servo drive, creating seven
axes of motion.
This high-speed labeling machine is designed for a unique heat-transfer decorating process for plastic containers. Baldor motion control products were selected
because of the power, reliability and flexibility they provide. Coupled with Baldor’s Mint easy-to-use programming language, the system captures, orients and
presents containers to the labeling heads for accurate label placement.
®
12 | Solutions Magazine | Number 9
“The system is sophisticated in the way
that all seven axes are moving at the
same time to control the paper and wax
label and the container,” says Ziegler.
“The paper label itself is floating on
a layer of wax, which is heated up just
enough to get the wax to liquefy. Then,
right at the point when we apply it to
the container, we heat the adhesive
up a little hotter so it adheres to the
container.”
Baldor’s NextMove e100 real-time Ethernet motion controller communicates with seven Baldor
MicroFlex e100 servo drives to create seven axes of motion in this application. This digital solution
reduces the wiring between the drives and the motion controller, improving set up time and increasing
reliability. These products were selected because they are easy to install, and user-friendly, and they offer
the precise performance required in this unique application.
Number 9 | Solutions Magazine | 13
F e at u r e s
F e at u r e s
That’s why when his company, based
in Burlington, Kentucky, was awarded
the contract to build 15 heat transfer
labeling machines for a large food
manufacturer, there was no doubt that
Baldor motion control products would
be used on these machines.
System integrator Steve Ziegler, with
Zigtronics Inc., also has a long history
working with Turner, Baldor and the
Cincinnati district office. He was a part
of this latest project from the beginning
and says the machine the team
designed is a very sophisticated piece
of equipment that uses a heat-transfer
process that labels three panels of a
round container in one motion, instead
of doing each panel individually.
“The container is moved into a nesting
nozzle that grabs the container and
indexes it to a specific mark putting
the container into position,” explains
Ziegler. “Next the label is applied using
a heat process to apply the label on in a
3% stretch onto the container before it
exits the machine. The label placement
has to be plus or minus 1/32" at the
part seam, and we rely on the Baldor
equipment to maintain this position
accuracy.”
The Baldor products selected to make
sure that the motion, position and
pressure are right every time include
the NextMove® e100 motion controller,
seven MicroFlex® e100s and seven servo
motors. Ziegler says because the motion
controller is an Ethernet Powerlink
integrated hub, it communicates to each
individual servo drive, creating seven
axes of motion.
This high-speed labeling machine is designed for a unique heat-transfer decorating process for plastic containers. Baldor motion control products were selected
because of the power, reliability and flexibility they provide. Coupled with Baldor’s Mint easy-to-use programming language, the system captures, orients and
presents containers to the labeling heads for accurate label placement.
®
12 | Solutions Magazine | Number 9
“The system is sophisticated in the way
that all seven axes are moving at the
same time to control the paper and wax
label and the container,” says Ziegler.
“The paper label itself is floating on
a layer of wax, which is heated up just
enough to get the wax to liquefy. Then,
right at the point when we apply it to
the container, we heat the adhesive
up a little hotter so it adheres to the
container.”
Baldor’s NextMove e100 real-time Ethernet motion controller communicates with seven Baldor
MicroFlex e100 servo drives to create seven axes of motion in this application. This digital solution
reduces the wiring between the drives and the motion controller, improving set up time and increasing
reliability. These products were selected because they are easy to install, and user-friendly, and they offer
the precise performance required in this unique application.
Number 9 | Solutions Magazine | 13
F e at u r e s
F e at u r e s
After more than two and a half years
in operation, in what Turner describes
as a harsh environment with high
temperatures and high humidity, the
machines have performed flawlessly with
no failures. He says the customer was
looking for a new machine that would
help them increase productivity, and
that’s just what’s happened.
“Others have tried to get my business, but I
continue to use Baldor motion control products
because it's a much easier package to work with,
the products perform and they are reliable.”
“The customer wanted labeling
equipment that would help reduce their
scrap rate,” says Turner. “In the past,
they had a scrap rate of 7% at 50 bottles
a minute. With this new equipment, that
rate has dropped to less than half of 1%
at 60 bottles a minute, and the customer
couldn’t be happier.”
Steve Ziegler
president, Zigtronics Inc.
As the system integrator, it’s Ziegler’s
responsibility to install the equipment
at the customer site and get it up and
running. He says what he likes about
using Baldor motion control products is
that he can design a complete machine
that quickly drops into place, requiring
nothing else but a connection to power
and air. But more importantly, Zeigler
requests quickly, and they’ve never been
disappointed.
“Baldor keeps products stocked, and
that kind of availability is so important
to us,” says Turner. “Plus, we get
fantastic support from sizing, product
selection and training. Bottom line is
that we get everything we want from
Baldor – that’s why we have partnered
with them for the past 10 years, and it’s
why they will be a part of our future."
Baldor Motion is Changing…
Introducing ABB Motion
Please note that the Baldor motion control
products and servo drives featured in this
story were installed prior to our transition
to the ABB Motion brand. The products
remain functionally unchanged, only the
exterior color and logo have changed.
says he likes the way his customers can
easily use the equipment.
“Within just a short amount of time,
I can train the customer on how to use
the products and the software because
it’s all designed to be user friendly,” says
Baldor motion control products are programmed to provide the right feed, placement and pressure for
the machine to apply heat transfer labels from a preprinted, continuous paper web to the container.
This new equipment has helped the end user become more efficient by taking its scrap rate of 7% at 50
containers per minute to less than half of 1% at 60 containers per minute.
Company officials say their long-term partnership with Baldor has helped them reach their goal of providing high-quality heat transfer labeling equipment
that generates the fastest speed possible with the most accurate label placement. Here, a Concept Machine & Design employee is working on four of the seven
Baldor BSM Series servo motors used on the machine. Designed for industrial applications, Baldor servo motors offer superior durability and proven reliability.
14 | Solutions Magazine | Number 9
Ziegler. “Plus, Baldor offers the software
for free and provides free upgrades via
the Internet – that’s a huge benefit to
both me and the customer. Others have
tried to get my business, but I continue
to use Baldor motion control products
because it’s a much easier package to
work with, the products perform, and
they are reliable.”
Quick access to products is also a key
reason Ziegler and Turner continue
to partner with Baldor. They build a
large amount of high-speed motion
equipment for all types of applications
and often have only a limited amount
of time to get the machine built,
installed and running. Turner says they
count on Baldor to respond to their
Turner Plastic Innovations, Inc.,
services the packaging industry with
on-time, quality custom decorating.
This labeling machine is using heat
transfer technology to decorate caps
for detergent bottles. With Baldor’s
NextMove e100 real-time Ethernet
motion controller and MicroFlex
e100 servo drives, the machine runs
200 caps per minute. Company
president James Turner says the
machine has run for nearly five years
with no failure. He says the Baldor
equipment is reliable, and that’s why
he continues to use these products on
all the equipment he builds.
Number 9 | Solutions Magazine | 15
F e at u r e s
F e at u r e s
After more than two and a half years
in operation, in what Turner describes
as a harsh environment with high
temperatures and high humidity, the
machines have performed flawlessly with
no failures. He says the customer was
looking for a new machine that would
help them increase productivity, and
that’s just what’s happened.
“Others have tried to get my business, but I
continue to use Baldor motion control products
because it's a much easier package to work with,
the products perform and they are reliable.”
“The customer wanted labeling
equipment that would help reduce their
scrap rate,” says Turner. “In the past,
they had a scrap rate of 7% at 50 bottles
a minute. With this new equipment, that
rate has dropped to less than half of 1%
at 60 bottles a minute, and the customer
couldn’t be happier.”
Steve Ziegler
president, Zigtronics Inc.
As the system integrator, it’s Ziegler’s
responsibility to install the equipment
at the customer site and get it up and
running. He says what he likes about
using Baldor motion control products is
that he can design a complete machine
that quickly drops into place, requiring
nothing else but a connection to power
and air. But more importantly, Zeigler
requests quickly, and they’ve never been
disappointed.
“Baldor keeps products stocked, and
that kind of availability is so important
to us,” says Turner. “Plus, we get
fantastic support from sizing, product
selection and training. Bottom line is
that we get everything we want from
Baldor – that’s why we have partnered
with them for the past 10 years, and it’s
why they will be a part of our future."
Baldor Motion is Changing…
Introducing ABB Motion
Please note that the Baldor motion control
products and servo drives featured in this
story were installed prior to our transition
to the ABB Motion brand. The products
remain functionally unchanged, only the
exterior color and logo have changed.
says he likes the way his customers can
easily use the equipment.
“Within just a short amount of time,
I can train the customer on how to use
the products and the software because
it’s all designed to be user friendly,” says
Baldor motion control products are programmed to provide the right feed, placement and pressure for
the machine to apply heat transfer labels from a preprinted, continuous paper web to the container.
This new equipment has helped the end user become more efficient by taking its scrap rate of 7% at 50
containers per minute to less than half of 1% at 60 containers per minute.
Company officials say their long-term partnership with Baldor has helped them reach their goal of providing high-quality heat transfer labeling equipment
that generates the fastest speed possible with the most accurate label placement. Here, a Concept Machine & Design employee is working on four of the seven
Baldor BSM Series servo motors used on the machine. Designed for industrial applications, Baldor servo motors offer superior durability and proven reliability.
14 | Solutions Magazine | Number 9
Ziegler. “Plus, Baldor offers the software
for free and provides free upgrades via
the Internet – that’s a huge benefit to
both me and the customer. Others have
tried to get my business, but I continue
to use Baldor motion control products
because it’s a much easier package to
work with, the products perform, and
they are reliable.”
Quick access to products is also a key
reason Ziegler and Turner continue
to partner with Baldor. They build a
large amount of high-speed motion
equipment for all types of applications
and often have only a limited amount
of time to get the machine built,
installed and running. Turner says they
count on Baldor to respond to their
Turner Plastic Innovations, Inc.,
services the packaging industry with
on-time, quality custom decorating.
This labeling machine is using heat
transfer technology to decorate caps
for detergent bottles. With Baldor’s
NextMove e100 real-time Ethernet
motion controller and MicroFlex
e100 servo drives, the machine runs
200 caps per minute. Company
president James Turner says the
machine has run for nearly five years
with no failure. He says the Baldor
equipment is reliable, and that’s why
he continues to use these products on
all the equipment he builds.
Number 9 | Solutions Magazine | 15
F e at u r e s
Domtar's
F e at u r e s
Marlboro
Paper Mill
Moves to
AC Technology
with Help from Baldor
All the Baldor•Reliance large AC motors on
the dryer drive line are variable speed, allowing
the process to be slowed down or speeded up,
depending on the grade of paper that is running.
16 | Solutions Magazine | Number 9
Number 9 | Solutions Magazine | 17
F e at u r e s
Domtar's
F e at u r e s
Marlboro
Paper Mill
Moves to
AC Technology
with Help from Baldor
All the Baldor•Reliance large AC motors on
the dryer drive line are variable speed, allowing
the process to be slowed down or speeded up,
depending on the grade of paper that is running.
16 | Solutions Magazine | Number 9
Number 9 | Solutions Magazine | 17
F e at u r e s
The Marlboro paper mill, located in
Bennettsville, South Carolina, was
originally opened by Willamette in
1990 and became part of Domtar in
2007. With one pulp line and one paper
machine, this mill has an annual paper
production capacity of up to 389,000
tons.
Shortly after becoming a part of
Domtar, mill officials determined
that they needed to move the mill’s
technology forward to be more in line
F e at u r e s
with the latest industry norm for paper
mill applications.
That meant converting existing DC
motors and drives to AC technology.
The cost of rebuilding DC motors and
the ongoing cost of brush maintenance
also contributed to the decision to make
the switch.
the right motors for the retrofit but
also the right company to trust with
this complex project. Rogers says they
looked at a number of manufacturers,
but in the end chose Baldor because of
the quality of the product and because
he and his team felt more comfortable
with the level of support they were
getting from Baldor versus the others.
Bill Rogers, manufacturing services
department manager at the Marlboro
mill, led the effort to find not only
“We had a preference for the
bearing lubrication design of the
Baldor•Reliance® large AC motors,”
This first Baldor•Reliance motor installed was this 1,500 HP variable speed, totally enclosed, blower-cooled AC unit on the paper machine fan pump. The
pump, located in the basement just below the paper machine, provides the stock flow used to put the fiber on the machine.
18 | Solutions Magazine | Number 9
Domtar had the option of using a 3,000 HP motor for its boiler-feed water pump system; however, it chose to use dual-tandem Baldor•Reliance 1,500 HP
variable speed, totally enclosed, blower-cooled AC motors. This engineered solution fit the existing electrical supply, so no changes had to be made to the
transformers supplying power.
Number 9 | Solutions Magazine | 19
F e at u r e s
The Marlboro paper mill, located in
Bennettsville, South Carolina, was
originally opened by Willamette in
1990 and became part of Domtar in
2007. With one pulp line and one paper
machine, this mill has an annual paper
production capacity of up to 389,000
tons.
Shortly after becoming a part of
Domtar, mill officials determined
that they needed to move the mill’s
technology forward to be more in line
F e at u r e s
with the latest industry norm for paper
mill applications.
That meant converting existing DC
motors and drives to AC technology.
The cost of rebuilding DC motors and
the ongoing cost of brush maintenance
also contributed to the decision to make
the switch.
the right motors for the retrofit but
also the right company to trust with
this complex project. Rogers says they
looked at a number of manufacturers,
but in the end chose Baldor because of
the quality of the product and because
he and his team felt more comfortable
with the level of support they were
getting from Baldor versus the others.
Bill Rogers, manufacturing services
department manager at the Marlboro
mill, led the effort to find not only
“We had a preference for the
bearing lubrication design of the
Baldor•Reliance® large AC motors,”
This first Baldor•Reliance motor installed was this 1,500 HP variable speed, totally enclosed, blower-cooled AC unit on the paper machine fan pump. The
pump, located in the basement just below the paper machine, provides the stock flow used to put the fiber on the machine.
18 | Solutions Magazine | Number 9
Domtar had the option of using a 3,000 HP motor for its boiler-feed water pump system; however, it chose to use dual-tandem Baldor•Reliance 1,500 HP
variable speed, totally enclosed, blower-cooled AC motors. This engineered solution fit the existing electrical supply, so no changes had to be made to the
transformers supplying power.
Number 9 | Solutions Magazine | 19
F e at u r e s
says Rogers. “But we also liked the
fact that Baldor engineers were willing
to work with our plant engineers to
study the options available prior to any
commitments being made to purchase
the motors. The Baldor team was very
helpful and provided a lot of background
and support engineering.”
The work that Rogers is referring
to was conducted by Baldor’s paper
and forest products industry team, a
group dedicated to supporting this
industry. The team visited the mill
on several occasions, studied the
application requirements and then made
recommendations for an engineered
solution. Michael Feldkirchner, Domtar’s
senior electrical project engineer, agrees
with Rogers that it was definitely good
support.
F e at u r e s
“Baldor went beyond what other
manufacturers did by supplying
us with engineers to come on-site
and look at our applications,” says
Feldkirchner. “They sent us reports
back for our review and made good
recommendations. They made sure
that what we selected worked now and
would work for future upgrades, as
well.”
With the decision made to purchase
Baldor motors, Feldkirchner began
working with engineers at the plant
Right: After reviewing and evaluating various
drive options, Domtar selected ABB drives because
officials have said they are the best product for the
job. Raw data collected by Domtar shows the mill
saved roughly 200 kVA of power with the new AC
drives/motor combination versus the DC products,
achieving a 10% reduction in electrical usage.
Domtar’s Marlboro Mill has an annual paper production capacity of up to 389,000 tons.
where the motors were being built.
Again, he says, the level of support he
received from the plant was greatly
appreciated.
“Baldor’s King’s Mountain plant was
very helpful in getting us the drawings
early in the process,” says Feldkirchner.
“We really appreciated the good job the
plant did in getting us the information
we needed.”
Baldor•Reliance V*S Master motors, like this 200 HP totally enclosed, fan-cooled unit on the dryer, are inverter duty AC motors designed to provide full load
torque continuously from 0 to base speed. The unique inverter duty insulation system in this motor eliminates the formation of corona, which can greatly
shorten motor life.
20 | Solutions Magazine | Number 9
The first Baldor•Reliance large AC
motor installed was a 1,500 HP variable
speed fan pump motor located in the
basement below the paper machine.
This was followed by two 1,500 HP
variable speed motors installed on the
boiler-feed water pump; a 1,500 HP
variable speed motor installed on the
biomass boiler-induced draft fan; and
finally a series of eight variable speed
AC motors, from 20 HP to 800 HP,
installed on the dryer section of the
paper machine. The majority of these
motors are on critical applications,
and any motor failure would stop the
paper-making process, costing the mill a
significant amount in lost production.
“Baldor went
beyond what other
manufacturers did
by supplying us with
engineers to come on-site
and look at our
applications.”
Michael Feldkirchner,
senior electrical project
manager,
Domtar's Marlboro
paper mill
Understandably, reliability is a top
concern for Rogers, but he says the
mill has gotten the performance and
reliability they expected from the
Baldor•Reliance motors installed.
“This project has been extremely
successful,” says Rogers. “These motors
have performed up to our expectations.
We had no issues at start up, no issues
with any of the motors, and everything
is performing as planned.”
Changing out all of the motors from
DC to AC was a major undertaking,
and despite his confidence in the
engineering support he received from
Baldor’s industry team, Feldkirchner
says he was still nervous about how
everything would turn out.
“Someone very wise told me that
anytime you touch a motor on a paper
machine it’s potentially a career-altering
decision,” says Feldkirchner. “But after
all of this time, we can look back and
know that we definitely made the right
decision.”
Number 9 | Solutions Magazine | 21
F e at u r e s
says Rogers. “But we also liked the
fact that Baldor engineers were willing
to work with our plant engineers to
study the options available prior to any
commitments being made to purchase
the motors. The Baldor team was very
helpful and provided a lot of background
and support engineering.”
The work that Rogers is referring
to was conducted by Baldor’s paper
and forest products industry team, a
group dedicated to supporting this
industry. The team visited the mill
on several occasions, studied the
application requirements and then made
recommendations for an engineered
solution. Michael Feldkirchner, Domtar’s
senior electrical project engineer, agrees
with Rogers that it was definitely good
support.
F e at u r e s
“Baldor went beyond what other
manufacturers did by supplying
us with engineers to come on-site
and look at our applications,” says
Feldkirchner. “They sent us reports
back for our review and made good
recommendations. They made sure
that what we selected worked now and
would work for future upgrades, as
well.”
With the decision made to purchase
Baldor motors, Feldkirchner began
working with engineers at the plant
Right: After reviewing and evaluating various
drive options, Domtar selected ABB drives because
officials have said they are the best product for the
job. Raw data collected by Domtar shows the mill
saved roughly 200 kVA of power with the new AC
drives/motor combination versus the DC products,
achieving a 10% reduction in electrical usage.
Domtar’s Marlboro Mill has an annual paper production capacity of up to 389,000 tons.
where the motors were being built.
Again, he says, the level of support he
received from the plant was greatly
appreciated.
“Baldor’s King’s Mountain plant was
very helpful in getting us the drawings
early in the process,” says Feldkirchner.
“We really appreciated the good job the
plant did in getting us the information
we needed.”
Baldor•Reliance V*S Master motors, like this 200 HP totally enclosed, fan-cooled unit on the dryer, are inverter duty AC motors designed to provide full load
torque continuously from 0 to base speed. The unique inverter duty insulation system in this motor eliminates the formation of corona, which can greatly
shorten motor life.
20 | Solutions Magazine | Number 9
The first Baldor•Reliance large AC
motor installed was a 1,500 HP variable
speed fan pump motor located in the
basement below the paper machine.
This was followed by two 1,500 HP
variable speed motors installed on the
boiler-feed water pump; a 1,500 HP
variable speed motor installed on the
biomass boiler-induced draft fan; and
finally a series of eight variable speed
AC motors, from 20 HP to 800 HP,
installed on the dryer section of the
paper machine. The majority of these
motors are on critical applications,
and any motor failure would stop the
paper-making process, costing the mill a
significant amount in lost production.
“Baldor went
beyond what other
manufacturers did
by supplying us with
engineers to come on-site
and look at our
applications.”
Michael Feldkirchner,
senior electrical project
manager,
Domtar's Marlboro
paper mill
Understandably, reliability is a top
concern for Rogers, but he says the
mill has gotten the performance and
reliability they expected from the
Baldor•Reliance motors installed.
“This project has been extremely
successful,” says Rogers. “These motors
have performed up to our expectations.
We had no issues at start up, no issues
with any of the motors, and everything
is performing as planned.”
Changing out all of the motors from
DC to AC was a major undertaking,
and despite his confidence in the
engineering support he received from
Baldor’s industry team, Feldkirchner
says he was still nervous about how
everything would turn out.
“Someone very wise told me that
anytime you touch a motor on a paper
machine it’s potentially a career-altering
decision,” says Feldkirchner. “But after
all of this time, we can look back and
know that we definitely made the right
decision.”
Number 9 | Solutions Magazine | 21
F e at u r e s
22 | Solutions Magazine | Number 9
F e at u r e s
Number 9 | Solutions Magazine | 23
F e at u r e s
22 | Solutions Magazine | Number 9
F e at u r e s
Number 9 | Solutions Magazine | 23
F e at u r e s
F e at u r e s
The Baldor•Reliance® SSE™ Stainless Steel Super-E® motor, with its all-stainless construction, including housing, conduit box and end plates, makes this
product impervious to rust and deterioration caused by high-pressure sanitizing. Premium external and internal bearing protection prevents water from entering
the motor. Encapsulation using Baldor’s E3 Effusion Epoxy Encapsulation™ process on the windings adds another level of moisture protection. The Dodge®
Quantis® E-Z Kleen gear reducer is manufactured with a 13-step coating system that provides greater than three times the corrosion resistance of standard
epoxy-painted units. E-Z Kleen reducers have a two-piece, harsh-duty sealing system that protects against high-pressure sprays and sanitizing solutions.
Malt is a processed form of barley and
is one of the basic ingredients used
to brew beer. Often referred to as the
“soul” of beer, malt provides most
of the complex carbohydrates and
sugars needed to give this beverage
its distinctive flavor and color. The
Malteurop Group, the world’s leading
malt producer headquartered in Reims,
France, has perfected the precise
control required to produce premium
quality malt barley.
Malteurop acquired U.S.-based ADM
Malting in 2008, including a malting
facility in Milwaukee, Wisconsin, a city
24 | Solutions Magazine | Number 9
historically linked to the beer industry.
Soon after, work began to upgrade the
facility, including one of the large malt
houses at the plant.
Gary McLoughlin, vice president
of operations for Malteurop North
America, says all 12 malting beds
needed to be upgraded, replacing aging
equipment with more reliable and more
efficient technology. Each bed is nearly
127 feet long and 18 feet wide and
holds 100 tons of cleaned and hydrated
barley. Over a four-day period, 11
separate screw mixers are continuously
moved back and forth through the bed,
while the barley germinates. Moisture
levels are maintained or raised during
this process by moving humidified air
through the barley. McLoughlin says
there is no room for error over this
time-critical process because equipment
failure can result in substandard barley
malt.
“Once we give the barley water and air,
there is no stopping the germination
process –– the barley doesn’t care that
we’ve had a breakdown, it just keeps
growing,” explains McLoughlin. “If
we are down too long, we’ll have to
throw the batch out, and if we can’t
evacuate the bed in time, we have a real
problem with backing up production
because there is always a batch waiting.
This is why equipment reliability is so
important to us.”
Dave Hinners, the facility’s project
engineer, led the in-house design effort
for the upgrade. He says the high
humidity required for the germination
process and the extensive cleaning
between batches has led to a high failure
rate for both mechanical and electrical
equipment. Working with Kurz Electric
Solutions, a local distributor helping
them with repair work, Hinners
Malthouse Project Engineer Dave Hinners says they chose a Baldor•Reliance RPM AC® motor for the
travel drive because it meets the unique requirements required for the application. When the travel drive
is moving back and forth turning the barley, it moves just under two feet per minute. But during the
unload, it moves nearly 100 feet per minute. “That’s over a 60-to-1 ratio, and we needed a motor that
could handle that wide range of speed with the torque that we needed,” says Hinners. “Because the RPM
AC motor offers continuous constant torque to zero speed, it’s the perfect choice for this machine.”
Number 9 | Solutions Magazine | 25
F e at u r e s
F e at u r e s
The Baldor•Reliance® SSE™ Stainless Steel Super-E® motor, with its all-stainless construction, including housing, conduit box and end plates, makes this
product impervious to rust and deterioration caused by high-pressure sanitizing. Premium external and internal bearing protection prevents water from entering
the motor. Encapsulation using Baldor’s E3 Effusion Epoxy Encapsulation™ process on the windings adds another level of moisture protection. The Dodge®
Quantis® E-Z Kleen gear reducer is manufactured with a 13-step coating system that provides greater than three times the corrosion resistance of standard
epoxy-painted units. E-Z Kleen reducers have a two-piece, harsh-duty sealing system that protects against high-pressure sprays and sanitizing solutions.
Malt is a processed form of barley and
is one of the basic ingredients used
to brew beer. Often referred to as the
“soul” of beer, malt provides most
of the complex carbohydrates and
sugars needed to give this beverage
its distinctive flavor and color. The
Malteurop Group, the world’s leading
malt producer headquartered in Reims,
France, has perfected the precise
control required to produce premium
quality malt barley.
Malteurop acquired U.S.-based ADM
Malting in 2008, including a malting
facility in Milwaukee, Wisconsin, a city
24 | Solutions Magazine | Number 9
historically linked to the beer industry.
Soon after, work began to upgrade the
facility, including one of the large malt
houses at the plant.
Gary McLoughlin, vice president
of operations for Malteurop North
America, says all 12 malting beds
needed to be upgraded, replacing aging
equipment with more reliable and more
efficient technology. Each bed is nearly
127 feet long and 18 feet wide and
holds 100 tons of cleaned and hydrated
barley. Over a four-day period, 11
separate screw mixers are continuously
moved back and forth through the bed,
while the barley germinates. Moisture
levels are maintained or raised during
this process by moving humidified air
through the barley. McLoughlin says
there is no room for error over this
time-critical process because equipment
failure can result in substandard barley
malt.
“Once we give the barley water and air,
there is no stopping the germination
process –– the barley doesn’t care that
we’ve had a breakdown, it just keeps
growing,” explains McLoughlin. “If
we are down too long, we’ll have to
throw the batch out, and if we can’t
evacuate the bed in time, we have a real
problem with backing up production
because there is always a batch waiting.
This is why equipment reliability is so
important to us.”
Dave Hinners, the facility’s project
engineer, led the in-house design effort
for the upgrade. He says the high
humidity required for the germination
process and the extensive cleaning
between batches has led to a high failure
rate for both mechanical and electrical
equipment. Working with Kurz Electric
Solutions, a local distributor helping
them with repair work, Hinners
Malthouse Project Engineer Dave Hinners says they chose a Baldor•Reliance RPM AC® motor for the
travel drive because it meets the unique requirements required for the application. When the travel drive
is moving back and forth turning the barley, it moves just under two feet per minute. But during the
unload, it moves nearly 100 feet per minute. “That’s over a 60-to-1 ratio, and we needed a motor that
could handle that wide range of speed with the torque that we needed,” says Hinners. “Because the RPM
AC motor offers continuous constant torque to zero speed, it’s the perfect choice for this machine.”
Number 9 | Solutions Magazine | 25
F e at u r e s
discussed how bearings were especially
troubling, difficult to maintain and even
more difficult to remove. When the
Kurz team demonstrated the features
of the Dodge Imperial™ bearing,
Hinners believed he may have found the
solution.
“The unique mounting method of this
bearing makes it easy to install but also
easy to remove, if needed,” says Hinners.
“But it’s the triple-lip sealing system
that really sold us on the Imperial. The
biggest enemy in our facility is water,
and if we can keep water out, a major
problem is solved.”
Needing to be certain before making
the final decision, an Imperial
bearing was installed to see how it
would perform. Hinners says after an
18-month test, he got the results he was
hoping for.
“Taking a bearing off in the past would
have involved hydraulics, torches and
saws,” says Hinners. “But the Imperial
F e at u r e s
was easy to get off. The sealing system
worked because this bearing looked
very good.”
“It's the triple-lip sealing
system that really sold
us on the Imperial. The
biggest enemy in our
facility is water, and if
we can keep water out, a
major problem is solved.”
Dave Hinners,
facility project engineer,
Malteurop Milwaukee
plant
While the bearing was under test, the
Malteurop team continued to work with
the Kurz team, the local Dodge field
sales engineer and Baldor’s Milwaukee
district office to put together the most
reliable motor and gearbox package.
The products had to be engineered to
withstand the harsh conditions, and
because this was a retro-fit, they had
to fit the existing envelope. Because
motors were failing due to severely
corroded housings, Mike Glynn, Kurz
vice president for marketing and new
business development, recommended
Baldor’s SSE Stainless Steel Super-E
motor.
Based on the success of the other
Baldor products used on the
germination beds, the Malteurop
team asked for a reliable gearing
solution for their screw conveyor
applications. Gene Gestwicki, plant
maintenance and project engineer,
says the existing units required
constant maintenance to keep them
running. When Kurz told Gestwicki
about the Dodge Motorized TorqueArm™ (MTA), a totally enclosed,
shaft-mounted speed reducer, he was
eager to try one. The product was a
hit right out of the box. “It was an
easy, straightforward installation,”
says Gestwicki. “Plus, everything is
sealed on the MTA, so it won’t be
affected by the environment. We
have more on order, and we are
going to continue to replace older
equipment with this new solution.”
“This stainless motor is designed to
perform in harsh conditions longer
than anything else available today,” says
Glynn. “And, to make sure we could
get the right reducer to fit, Dodge sales
engineer Brian Koch helped us with
a design for the Dodge Quantis E-Z
Kleen. And just like the bearing test,
we placed a plate from the unit in the
environment to prove that the reducers’
13-step coating system would hold up
without rusting –– and it did.”
As an added benefit, Baldor preassembled the motors and gearboxes,
so the Malteurop team didn’t have to
worry about assembly on-site.
With the project nearly complete,
McLoughlin says he’s pleased with
the results. Between the performance,
reliability and energy savings these
products offer, he is convinced they
have found the right solution. He
credits the success to the skills of the
in-house engineering team and the
expertise provided by valued partners.
“This has been a significant project for
us,” says McLoughlin. But with this
collaboration and the attention to detail,
the project is a success. “We knew what
we wanted, and with help, we got what
we wanted. And now we believe we have
the right solution.”
Malted barley is the main
ingredient in beer, and
Malteurop is the world’s
leading malt producer. The
Malteurop North America
plant in Milwaukee produces
220,000 tons of Pilsen-style
malt used by local brewers and
by companies in Kentucky
and Tennessee that produce
bourbon and malt whisky.
The Malteurop team selected Dodge Imperial roller bearings because of the patented triple-lip contact sealing system that prevents water and other
contaminants from entering the bearing. The team is also pleased with the adapter mounting system that makes these bearings easy to install and remove.
26 | Solutions Magazine | Number 9
Number 9 | Solutions Magazine | 27
F e at u r e s
discussed how bearings were especially
troubling, difficult to maintain and even
more difficult to remove. When the
Kurz team demonstrated the features
of the Dodge Imperial™ bearing,
Hinners believed he may have found the
solution.
“The unique mounting method of this
bearing makes it easy to install but also
easy to remove, if needed,” says Hinners.
“But it’s the triple-lip sealing system
that really sold us on the Imperial. The
biggest enemy in our facility is water,
and if we can keep water out, a major
problem is solved.”
Needing to be certain before making
the final decision, an Imperial
bearing was installed to see how it
would perform. Hinners says after an
18-month test, he got the results he was
hoping for.
“Taking a bearing off in the past would
have involved hydraulics, torches and
saws,” says Hinners. “But the Imperial
F e at u r e s
was easy to get off. The sealing system
worked because this bearing looked
very good.”
“It's the triple-lip sealing
system that really sold
us on the Imperial. The
biggest enemy in our
facility is water, and if
we can keep water out, a
major problem is solved.”
Dave Hinners,
facility project engineer,
Malteurop Milwaukee
plant
While the bearing was under test, the
Malteurop team continued to work with
the Kurz team, the local Dodge field
sales engineer and Baldor’s Milwaukee
district office to put together the most
reliable motor and gearbox package.
The products had to be engineered to
withstand the harsh conditions, and
because this was a retro-fit, they had
to fit the existing envelope. Because
motors were failing due to severely
corroded housings, Mike Glynn, Kurz
vice president for marketing and new
business development, recommended
Baldor’s SSE Stainless Steel Super-E
motor.
Based on the success of the other
Baldor products used on the
germination beds, the Malteurop
team asked for a reliable gearing
solution for their screw conveyor
applications. Gene Gestwicki, plant
maintenance and project engineer,
says the existing units required
constant maintenance to keep them
running. When Kurz told Gestwicki
about the Dodge Motorized TorqueArm™ (MTA), a totally enclosed,
shaft-mounted speed reducer, he was
eager to try one. The product was a
hit right out of the box. “It was an
easy, straightforward installation,”
says Gestwicki. “Plus, everything is
sealed on the MTA, so it won’t be
affected by the environment. We
have more on order, and we are
going to continue to replace older
equipment with this new solution.”
“This stainless motor is designed to
perform in harsh conditions longer
than anything else available today,” says
Glynn. “And, to make sure we could
get the right reducer to fit, Dodge sales
engineer Brian Koch helped us with
a design for the Dodge Quantis E-Z
Kleen. And just like the bearing test,
we placed a plate from the unit in the
environment to prove that the reducers’
13-step coating system would hold up
without rusting –– and it did.”
As an added benefit, Baldor preassembled the motors and gearboxes,
so the Malteurop team didn’t have to
worry about assembly on-site.
With the project nearly complete,
McLoughlin says he’s pleased with
the results. Between the performance,
reliability and energy savings these
products offer, he is convinced they
have found the right solution. He
credits the success to the skills of the
in-house engineering team and the
expertise provided by valued partners.
“This has been a significant project for
us,” says McLoughlin. But with this
collaboration and the attention to detail,
the project is a success. “We knew what
we wanted, and with help, we got what
we wanted. And now we believe we have
the right solution.”
Malted barley is the main
ingredient in beer, and
Malteurop is the world’s
leading malt producer. The
Malteurop North America
plant in Milwaukee produces
220,000 tons of Pilsen-style
malt used by local brewers and
by companies in Kentucky
and Tennessee that produce
bourbon and malt whisky.
The Malteurop team selected Dodge Imperial roller bearings because of the patented triple-lip contact sealing system that prevents water and other
contaminants from entering the bearing. The team is also pleased with the adapter mounting system that makes these bearings easy to install and remove.
26 | Solutions Magazine | Number 9
Number 9 | Solutions Magazine | 27
BALDOR’S DODGE
®
MAGNAGEAR IN-STOCK PROGRAM
™
28 | Solutions Magazine | Number 9
Gets Barge
Conveyor
Back Up
and Running
Number 9 | Solutions Magazine | 29
BALDOR’S DODGE
®
MAGNAGEAR IN-STOCK PROGRAM
™
28 | Solutions Magazine | Number 9
Gets Barge
Conveyor
Back Up
and Running
Number 9 | Solutions Magazine | 29
F e at u r e s
F e at u r e s
“This experience has
shown me the capability
of the company and
the ‘can do’ attitude of
the people behind the
products.”
Jim McLain,
co-owner,
Allied Bearing & Supply
head, they could not afford to wait
eight to 10 weeks for a replacement.
Matherne says that’s when they decided
to call Jim McLain, co-owner of Allied
Bearing & Supply.
The Louisiana Mid-Stream One (LMO) is a unique barge-mounted conveying system with quality control features not found in other midstream loading
operations, including a magnet, mechanical sampling system, belt scale and water drainage. The LMO can simultaneously feed and combine product from
multiple barges to meet quality specifications, enhancing the quality of export coal.
In August 2011, Baldor launched the
Dodge MagnaGear in-stock program,
designed to help customers quickly
replace failed competitor units. By
Baldor stocking the most common sizes
and ratios of this power-dense, heavyduty large gearbox, customers would no
longer have to wait weeks and weeks to
get a replacement unit.
The timing of the program could not
have been better for the owners of the
Louisiana Mid-Stream One (LMO),
a unique barge-mounted conveying
system located on the Mississippi River
near New Orleans. Working in tandem
with a separate barge-mounted crane,
coal from a barge is directly fed into
30 | Solutions Magazine | Number 9
the receiving hoppers of the LMO.
After the coal is combined, it travels up
a series of conveyors to a retractable
loading boom that feeds an ocean-going
export vessel.
The LMO, a brand new rig, was
scheduled to start loading vessels in
early September 2011. But, during the
final test prior to the first load out, a
catastrophic failure of one of the three
gearboxes on the conveyor system shut
the rig down. Company representative
Andy Matherne said they already had
vessels booked in anticipation of the
LMO start-up, and every day they
couldn’t load coal was going to cost his
company a great deal of money.
“We are allowed a certain amount of
time to load a vessel, but once we go
beyond that, we have to pay a penalty,”
explains Matherne. “Typically it’s about
twenty thousand dollars per day, but
in this particular circumstance, with so
many vessels on anchor waiting to come
in, we were sitting on fifty thousand
dollars a day. Obviously the longer it
took for us to get running, the more
money it was going to cost us.”
The situation was frustrating to the
LMO team because, according to
Matherne, they couldn’t get the kind
of help they needed from the gearbox
manufacturer. With a fifty thousand
dollar a day penalty hanging over their
“I have had a long relationship with
Jim, and he has provided equipment and
expertise for us on many other projects,”
says Matherne. “When it comes to
conveying equipment and gearboxes,
Jim knows more about this kind of
equipment than anyone else I know. We
were confident that if anyone could help
us out, it was Jim.”
McLain says he received an email with
a photo of the failed gearbox asking if
he could help late on Sunday, August
28, 2011. After getting more details
on Monday, he believed he could find
a gearbox by taking advantage of the
new MagnaGear quick-ship program.
Not only did he find the right size
MagnaGear to replace the failed
gearbox, but he also found two more
units in case his customer wanted to
change out the other units on the rig.
On Tuesday, he presented the solution
to the LMO team.
“By Wednesday, we got the order for all
three MagnaGear reducers, because the
customer didn’t want to take any more
chances with gearboxes,” says McLain.
“I know that the team jumped through
Not only did the customer get the MagnaGear reducers in three days, but Jim McLain, with Allied
Bearing & Supply, says the customer got a product much better suited for this application. He says the
MagnaGear reducers provide twice the output torque than the boxes they replaced, plus the right-angle
configuration of the reducer is a perfect fit for this conveyor design.
hoops at the Dodge gear plant to get
couplings rebored and get additional
shaft fans, but everything showed up at
the LMO site on Saturday. With a lot
of work behind the scenes, we were able
to help a customer get out of a very bad
situation.”
but McLain says they actually got a
superior product that’s much better
suited for this conveyor application.
He says Dodge gearing is known for
reliability, and because of its powerdense design, the MagnaGear offers
more power in a smaller package.
Not only did the customer get the
reducers in just a couple of days,
“The MagnaGear reducers provide
the output torque twice of the boxes
Number 9 | Solutions Magazine | 31
F e at u r e s
F e at u r e s
“This experience has
shown me the capability
of the company and
the ‘can do’ attitude of
the people behind the
products.”
Jim McLain,
co-owner,
Allied Bearing & Supply
head, they could not afford to wait
eight to 10 weeks for a replacement.
Matherne says that’s when they decided
to call Jim McLain, co-owner of Allied
Bearing & Supply.
The Louisiana Mid-Stream One (LMO) is a unique barge-mounted conveying system with quality control features not found in other midstream loading
operations, including a magnet, mechanical sampling system, belt scale and water drainage. The LMO can simultaneously feed and combine product from
multiple barges to meet quality specifications, enhancing the quality of export coal.
In August 2011, Baldor launched the
Dodge MagnaGear in-stock program,
designed to help customers quickly
replace failed competitor units. By
Baldor stocking the most common sizes
and ratios of this power-dense, heavyduty large gearbox, customers would no
longer have to wait weeks and weeks to
get a replacement unit.
The timing of the program could not
have been better for the owners of the
Louisiana Mid-Stream One (LMO),
a unique barge-mounted conveying
system located on the Mississippi River
near New Orleans. Working in tandem
with a separate barge-mounted crane,
coal from a barge is directly fed into
30 | Solutions Magazine | Number 9
the receiving hoppers of the LMO.
After the coal is combined, it travels up
a series of conveyors to a retractable
loading boom that feeds an ocean-going
export vessel.
The LMO, a brand new rig, was
scheduled to start loading vessels in
early September 2011. But, during the
final test prior to the first load out, a
catastrophic failure of one of the three
gearboxes on the conveyor system shut
the rig down. Company representative
Andy Matherne said they already had
vessels booked in anticipation of the
LMO start-up, and every day they
couldn’t load coal was going to cost his
company a great deal of money.
“We are allowed a certain amount of
time to load a vessel, but once we go
beyond that, we have to pay a penalty,”
explains Matherne. “Typically it’s about
twenty thousand dollars per day, but
in this particular circumstance, with so
many vessels on anchor waiting to come
in, we were sitting on fifty thousand
dollars a day. Obviously the longer it
took for us to get running, the more
money it was going to cost us.”
The situation was frustrating to the
LMO team because, according to
Matherne, they couldn’t get the kind
of help they needed from the gearbox
manufacturer. With a fifty thousand
dollar a day penalty hanging over their
“I have had a long relationship with
Jim, and he has provided equipment and
expertise for us on many other projects,”
says Matherne. “When it comes to
conveying equipment and gearboxes,
Jim knows more about this kind of
equipment than anyone else I know. We
were confident that if anyone could help
us out, it was Jim.”
McLain says he received an email with
a photo of the failed gearbox asking if
he could help late on Sunday, August
28, 2011. After getting more details
on Monday, he believed he could find
a gearbox by taking advantage of the
new MagnaGear quick-ship program.
Not only did he find the right size
MagnaGear to replace the failed
gearbox, but he also found two more
units in case his customer wanted to
change out the other units on the rig.
On Tuesday, he presented the solution
to the LMO team.
“By Wednesday, we got the order for all
three MagnaGear reducers, because the
customer didn’t want to take any more
chances with gearboxes,” says McLain.
“I know that the team jumped through
Not only did the customer get the MagnaGear reducers in three days, but Jim McLain, with Allied
Bearing & Supply, says the customer got a product much better suited for this application. He says the
MagnaGear reducers provide twice the output torque than the boxes they replaced, plus the right-angle
configuration of the reducer is a perfect fit for this conveyor design.
hoops at the Dodge gear plant to get
couplings rebored and get additional
shaft fans, but everything showed up at
the LMO site on Saturday. With a lot
of work behind the scenes, we were able
to help a customer get out of a very bad
situation.”
but McLain says they actually got a
superior product that’s much better
suited for this conveyor application.
He says Dodge gearing is known for
reliability, and because of its powerdense design, the MagnaGear offers
more power in a smaller package.
Not only did the customer get the
reducers in just a couple of days,
“The MagnaGear reducers provide
the output torque twice of the boxes
Number 9 | Solutions Magazine | 31
F e at u r e s
they replaced,” says McLain. “Plus,
because it’s available in a right-angle
configuration, it was a perfect fit for this
conveyor design. These reducers are
built for tough environments, and they
are going to last for a very long time.”
Matherne gives McLain the credit for
quickly finding the solution that ended
up saving the company a great deal of
money. For his part, McLain says it’s
this kind of experience that really makes
him proud to be a Dodge distributor.
“You look across the Dodge product
line, and you see the quality and a
company that tries to do more with
products, not less,” says McLain. “This
experience has also shown me the
capability of the company and the ‘can
do’ attitude of the people behind the
products. There were a lot of hoops to
jump through and a lot of extra work
to get these gearboxes delivered to the
customer this quickly, and it speaks very
highly of all of the people who were
involved.”
Based on the success of the
MagnaGears running on the
LMO, when a gearbox failed on
one of the four feeders on the rig,
McLain recommended the Dodge
Motorized Torque-Arm™ (MTA)
as a replacement. “The customer
wanted to get away from the parallel
shaft overhung design of the failed
gearbox,” says McLain. “The MTA is
the ideal choice because it eliminates
the overhung load and all of the
issues they had with couplings and
alignment. The MTA will be easier
for them to maintain, plus it gives
the employees more room to work.
Because the Dodge MagnaGear in-stock program includes the most common sizes and ratios of this heavy-duty gearbox, customers now have an option of
quickly replacing failed competitor units. Instead of waiting up to 10 weeks for a replacement from the original manufacturer, the LMO team was able to get
three right-angle Dodge units, like this one, in only three days after the order was placed.
32 | Solutions Magazine | Number 9
The Industrial Choice
When it comes to industrial electric motors, power
transmission products and drives, no other manufacturer
offers more than Baldor...that is why Baldor is The Industrial
Choice! Whether your application requires a fractional
or 15,000 Hp motor, a variable frequency drive, mounted
bearings or gearing, a pulley or sheave or even a standby
generator, Baldor is the choice most preferred by industry.
• Superior Reliability
When your next project demands the most reliable and
energy efficient products available, look to Baldor as your
one source for more industrial solutions.
• Local Sales and Support
baldor.com
• Quickest Delivery Available
479-646-4711
• Unmatched Quality
F e at u r e s
they replaced,” says McLain. “Plus,
because it’s available in a right-angle
configuration, it was a perfect fit for this
conveyor design. These reducers are
built for tough environments, and they
are going to last for a very long time.”
Matherne gives McLain the credit for
quickly finding the solution that ended
up saving the company a great deal of
money. For his part, McLain says it’s
this kind of experience that really makes
him proud to be a Dodge distributor.
“You look across the Dodge product
line, and you see the quality and a
company that tries to do more with
products, not less,” says McLain. “This
experience has also shown me the
capability of the company and the ‘can
do’ attitude of the people behind the
products. There were a lot of hoops to
jump through and a lot of extra work
to get these gearboxes delivered to the
customer this quickly, and it speaks very
highly of all of the people who were
involved.”
Based on the success of the
MagnaGears running on the
LMO, when a gearbox failed on
one of the four feeders on the rig,
McLain recommended the Dodge
Motorized Torque-Arm™ (MTA)
as a replacement. “The customer
wanted to get away from the parallel
shaft overhung design of the failed
gearbox,” says McLain. “The MTA is
the ideal choice because it eliminates
the overhung load and all of the
issues they had with couplings and
alignment. The MTA will be easier
for them to maintain, plus it gives
the employees more room to work.
Because the Dodge MagnaGear in-stock program includes the most common sizes and ratios of this heavy-duty gearbox, customers now have an option of
quickly replacing failed competitor units. Instead of waiting up to 10 weeks for a replacement from the original manufacturer, the LMO team was able to get
three right-angle Dodge units, like this one, in only three days after the order was placed.
32 | Solutions Magazine | Number 9
The Industrial Choice
When it comes to industrial electric motors, power
transmission products and drives, no other manufacturer
offers more than Baldor...that is why Baldor is The Industrial
Choice! Whether your application requires a fractional
or 15,000 Hp motor, a variable frequency drive, mounted
bearings or gearing, a pulley or sheave or even a standby
generator, Baldor is the choice most preferred by industry.
• Superior Reliability
When your next project demands the most reliable and
energy efficient products available, look to Baldor as your
one source for more industrial solutions.
• Local Sales and Support
baldor.com
• Quickest Delivery Available
479-646-4711
• Unmatched Quality
solutions
A Publication Featuring Baldor Electric Company Products
Number 9
magazine
Domtar's
Marlboro
Paper Mill
P.O. Box 2400, Fort Smith, AR 72902-2400 USA, Ph: (1) 479.646.4711, Fax: (1) 479.648.5792, International Fax: (1) 479.648.5895
baldor.com
©2012 Baldor Electric Company
Solutions0812
All Rights Reserved. Printed in USA.
X/XX-XX-13M
Pl u s
Moves to
AC Technology
with Help from Baldor
Baldor•Reliance® Large AC Motors
Installed Ten Years Ago at Holcim’s Holly Hill Plant
Continue to Provide Reliable Service
Malteurop North America
Selects Reliable Baldor Products for Malthouse Upgrade
1/--страниц
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