Tissue Processing Facility Saves ~ $165,000 and Reduces Line Maintenance
The Challenge
A major specialty paper products facility was facing significant challenges with their high-speed conveyors, which process facial tissues at speeds of up to approximately 360 feet per minute (FPM). After approximately two months of operation, the current manufacturer’s conveyor belts and nose-over rollers would fail. Despite multiple belt replacements the failures persisted, impacting production efficiency and increasing maintenance costs.
The paper products team turned to Regal Rexnord to provide a new solution. The application required a robust low back pressure chain that could:
- Handle high-speed conveying
- Withstand an abrasive dusty environment
- Deliver belt service life greater than three months
Due to the high speed required by the conveyor line, possible solution options were limited.
The Solution
Regal Rexnord collaborated with both the OEM and the customer to assess the conveyor operation. Upon inspection, issues with the nose-over roller material selection were identified, along with excessive chain elongation and wear due to the speed of the conveyor.
The team recommended installing the Rexnord® 1533 Series Low Backline Pressure (LBP) MatTop® Chain, a solution designed for durability, high-speed performance, and reduced noise levels.
The Rexnord 1533 Series Chain was installed, and recommendations were made to improve conveyor design and set up. This implementation included:
- Rexnord sprocket wrap return systems
- Increasing the number of dynamic nose-over rollers
- Addition of ValuGuide® return rollers
- Improved the catenary sag profile
- Replaced existing suppliers’ belt with Rexnord 1533 Series LBP MatTop Chain
The Results
- Immediate Improvements: After just one week of operation, the conveyor ran smoothly without requiring adjustments, and noise levels were noticeably reduced compared to the previous supplier’s chain.
- Sustained Performance: After six months, the 1533 Series Chain showed minimal signs of wear or elongation, far exceeding the previous chain’s lifespan.
- Enhanced Durability: The chain handles frequent starts and stops effectively, maintaining its integrity despite operating in a high-dust environment.
- Customer Satisfaction: Both the customer and the OEM were highly satisfied with the chain’s performance and Regal Rexnord’s consultative approach to solving the problem.
- Cost Savings: The customer recognized significant cost savings and was able to avoid lost revenue due to equipment downtime. The following chart outlines the recognized savings.
The customer is planning to implement the 1533 Series Chain on additional lines, bringing their total estimated savings to over $500,000.
Cost Avoidance |
Savings |
Calculations |
| New Belt Replacement Savings Reduce yearly belt replacement per line from 4 times to zero | $48,000 |
|
| Labor Costs Reduction of employee time spent on replacement if premature belt failure per line | $1,600 |
|
| Cost Savings (per line) | $49,600 |
Additional savings will be realized across multiple production lines |
|
Lost Production Revenue* Avoid revenue loss due to production downtime |
$120,000 |
|
| Total Saving (per line) | $169,600 |
|
Conclusion
By switching to Rexnord’s 1533 Series LBP MatTop Chain, the manufacturer successfully improved the conveyor’s reliability, reduced maintenance downtime, and achieved long-term cost savings. The chain’s superior durability, lower noise levels, and ability to handle high-speed, abrasive conditions made it the ideal solution for this demanding tissue production environment.
Calculate your potential savings above and contact Regal Rexnord to learn more.