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

Description Of Problem

A national distribution warehouse was experiencing repeated problems on various conveyor ship lines with a Regal 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 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 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




 

 

* Viton is believed to be the trademark of The Chemours Company and is not owned or controlled by Regal Beloit Corporation.

 

Brands

This name is used, please enter another
{0} was created successfully.
{0} was deleted successfully.
New password and confirm password do not match.
The password entered does not comply with our password policy. Please try again.
The password entered does not comply with our password policy. Please try again.
You have already access to entered account.
Account already added
Please select an account
The entered account number is not valid or the account is not yet transitioned for use at Regalbeloit.com.
You must provide a valid account number to be added. Please contact your Sales Representative or Account Administrator if you don’t know your Account Number.
Please select Additional Access checkbox.
Please enter your address.
Please enter your address cont.
Please check to agree with Terms of Use and Privacy Policy.
Please enter your city.
Please enter your company name.
Please enter confirm password.
Please select your country.
Please enter a valid format for your email address.
Please enter your email address.
Please enter your first name.
Please review and select a warehouse for Catalog/Part Numbers: {0}
Please enter your job title.
Please enter your last name.
The current password entered does not match your password or new password is the same like one of the previous or password changed last 30 days.
Profile updated successfully.
Error while request access.
Registration Information has been received.   Thank you for your interest in Regal.
Please enter new password.
Please enter old password.
Please enter a valid format for your phone number.
Please enter your phone number.
Please enter a valid format for your extension.
Please select at least one product category.
Please verify you are not a robot.
Registration Information has been received.   Thank you for your interest in Regal.
You must provide the name of a Regal Beloit employee who can confirm your need for access to Genteq technical documents.
Please select your state.
This email is already in use. Please log in.
Please enter your zip code.
Your session has timed out. You must log in again to access secure content. Any work on the current page will be lost.
You can order maximum {2} quantity for item {0}.
The following items have been added to your cart: {0}