Distribution Warehouse Saves Over $300,000
Application
Conveyor Ship Lines
Industry
Athletic Shoes and Apparel
Solution Type
Improved energy efficiency, increased uptime, SKU reduction with HERA® Gear Drives
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Description Of Problem
A national distribution warehouse was experiencing repeated problems on various conveyor ship lines with a Regal Rexnord competitor’s worm gearboxes. The gearboxes were leaking oil due to various seal failures and subsequently dripped oil on the merchandise. This nuisance caused maintenance personnel to shut down the lines, replace the gearboxes and mandate drip pans in each gearbox location. On average, maintenance personnel were replacing 35 gearboxes a month, costing the warehouse over $18,500 a month in unplanned downtime, not including the cost of gearboxes and maintenance.
Solution
Regal Rexnord engineers recommended the Hub City® HERA High Efficiency Right Angle gear drive. During the interchange from the competitor’s units to the HERA gear drives, it was found that the warehouse was using a 2HP motor that was oversized for the application. Therefore, the Regal Rexnord engineers also recommended that they downsize to a 1.5HP motor. This change on each motor resulted in an energy savings of $80,000 annually. The HERA units have been up and running with no issues for 28 months and counting. They have saved the warehouse over $300,000 with plans to implement the HERA solution on their remaining 50+ miles of conveyor lines and at other locations in North America!
Benefits Seen by the Warehouse Included
- Increased uptime and reduction in labor costs
- Increased torque density and efficiency allow for downsizing of units and motors
- Viton®* double lip seals protect against leaks
- Reduce/Consolidate storeroom inventory with less SKUs
- At least 90% efficiency (all ratios)
- $300,000+ annual savings
HERA® Gear Drives - Features and Benefits
- At least 90% efficiency in all ratios with up to 40% reduction in energy
- Torque-dense up to double the capacity of worm drives
- Wide torque capacity and modular shaft
- Base and flange components allow for HERA gear drives to interchange with worm reducers from 1.75 to 6 in. (44.45 to 152.4 mm) center distance
- Filled with PAG460 premium synthetic lubricant for enhanced efficiency (Meets USDA H1)
- Viton® Double Lip Seals protect against leaks
at higher temperatures
Worm System
Annual Operating Cost (total): $1,211
Based on internal test results
HERA System
Annual Operating Cost (total): $744
Based on internal test results
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