Distribution Warehouse Saves Over $300,000


Conveyor Ship Lines



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.



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.



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