Solutions Magazine - 3

Switching to Dodge® IMPERIAL™ BearingsHelps Horizon Milling Grind Out the Savings

The Secret is OutBaldor Products are a Key Ingredient in Bush's Best Production Success

Baldor Motion Control Products Help Martin Guitar

Feel The Difference


Feel The Difference

solutionsm a g a z i n eA Publication Featuring Baldor Electric Company Products Number 3

Plus

The New Gearmotor Gold Standard

©2008 Baldor Electric Company

• Energy Efficient

• Unmatched Quality

• Superior Reliability

• Quickest Delivery Available

The new DODGE® QUANTIS® Gold gearmotor combines the Baldor•Reliance® premium efficient Super-E® motor with the superior QUANTIS gearbox, making the QUANTIS Gold the most energy efficient, coolest running gearmotor in the world.

Available as in-line helical or right angle helical bevel c-face units, 1/2 to 10 Hp, the QUANTIS Gold raises gearmotor energy efficiency, quality and reliability to a new gold standard.

dodge-pt.com baldor.com

Cover: PG 14

Contents Number 3 Solutions Magazine Featuring Baldor•Reliance & Dodge Products www.baldor.com

24 New Drive System Package from Baldor

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 contact [email protected]

www.baldor.com

2 Briefings

6 Legislation Mandates Use of More Energy Efficient Motors...

8 The Secret is Out Baldor Products are a Key Ingredient in Bush's Best Production Success

14 Baldor Motion Control Products

20 Switching to Dodge® IMPERIAL™ Bearings

28 Baldor's Dodge® GRIP TIGHT® Bearings

But Why Wait?

Help Martin Guitar Feel the Difference

Helps Horizon Milling Grind out the Savings

Offers Mining Operations a Complete Solution

Double Uptime and Cut Costs for United Kingdom's Leading Tire Recycler

Briefings

2 | Solutions Magazine | Number 3

Baldor officials, employees, customers, suppliers and local dignitaries celebrated the grand opening of Baldor’s new Shanghai facility on August 12, 2008. The 20,000 square meter plant, twice the size of the previous facility, will continue to manufacture gear products, but will also produce Sleevoil® bearings and a line

of energy-efficient industrial motors to better serve the Asian market.

“We needed to expand and open this facility in order to meet the growing demands of our customers in this region,” states John McFarland, Chairman and Chief Executive Officer, Baldor Electric Company. “Our goal

Baldor Expands plant in shanghai to BEttEr sErvE CustomErs in asia

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Number 3 | Solutions Magazine | 3

is to be close to our customers so we can quickly provide superior quality products as their businesses grow. The strategy is to be a “local company” in a global market.”

China is now the largest market in the world for motors and Baldor’s expanded capabilities will allow the company to create the same competitive advantages in China that have been established in the United States.

“We are proud of the great job our employees in China are doing to make quality products and provide the high level of service expected by our customers in Asia Pacific,” states Michael Cinquemani, Executive Vice President-Dodge and International, Baldor Electric Company. “I am confident in our team and their ability to do great things for our customers with this expanded capability. This plant represents our commitment to global growth for Baldor Electric.”

Utilizing the same lean manufacturing processes as Baldor plants in the United States, the company’s China facility will also house a center of excellence with a

Above: During the grand opening of the new facility in Shanghai, John McFarland, Chairman and Chief Executive Officer, Baldor Electric Company (left) had the opportunity to meet many Baldor employees and customers, including PengYong Tan, managing director, Baldor Electric Asia (center), and Jimmy Hadinata, general manager of PT Suprabakti Mandiri (right), a distributor in Indonesia.

staff of experienced engineers to support key industries important in the region.

The company first began manufacturing in China in 1998 with the production of Dodge CSTs, a large gearing product used in mining applications. Today, this product is considered the industry

standard, with more than 1,000 units being sold in China and India.

In addition to the new plant to support and serve this expanding region, Baldor also has offices in China, Australia, Japan, Singapore and India.


Briefings

Baldor is now offering new Short Series Brake motors ready for immediate delivery from stock. Short Series Brake Motors (SSB) feature an integral Dodge® spring set brake for a compact and cost effective design. The DC brake is magnetically released with a built-in single-phase rectifier and has a manual release lever. Brake leads are brought to the motor conduit box for connecting to the motor leads or connecting separately when used with an inverter. Available for 230/460 and 575 volt operation in NEMA frame sizes 56 through 184 and in 1/2 through 5 HP, the brake motors are UL/CSA recognized and CE certified. 56-140 frames have low profile top-mounted conduit boxes and are inverter ready.

Baldor is expanding the Dodge ULTRA KLEEN® right angle, worm gear reducer line, plus offering 24 to 48 hour shipment on most sizes. Available in quill and 3-piece coupled input, and solid or hollow output, these stainless steel gear reducers offer ultimate washdown protection and include premium features the competition doesn’t offer. Now available in five sizes;

Baldor offErs short sEriEs BrakE motors

Baldor's dodgE® ultra klEEn® rEduCErs now availaBlE in morE sizEs and improvEd lEad timEs

143-145TY and 143-145TYC frame motors have a special base with slots used on OEM conveyors. Baldor short series brake motors feature

a two-year warranty. Typical applications include unit and baggage handling, conveyors, packaging equipment, machine tools, hoists, and door

operators. Baldor offers a wide range of stock brake motors through 30 HP using Dodge D-series brakes and Stearns

brakes.

17, 21, 23, 26 and 30, with center distances from 1.75 inch to 3.00 inch, these reducers include a totally enclosed ventless sealing system that contains a factory filled synthetic lubricant eliminating the need for routine oil changes. There is a wide selection of units available with same day air shipment if the product is ordered by noon EST, or next business day

air if the order is received after noon EST. All ULTRA KLEEN reducers are manufactured with premium 316 stainless steel housings, and are factory filled with H1 food grade synthetic lubricant. The reducers are protected by a two-piece harsh duty output sealing system that includes an axial sealing lip for superior wear and contamination exclusion, and a wave seal with optimized contact pressure for reduced

heat generation and wear. Washdown accessories for the ULTRA KLEEN include stainless steel straight bore bushings, stainless steel GRIP TIGHT® bushings, and a stainless steel bolt-on base kit and output flange kit. The Dodge ULTRA KLEEN stainless steel reducer is the best choice for ultimate washdown protection or where “paint free” specification is required.

Baldor with one of the largest power transmission component product offerings in North America.

“Maska’s sheaves and bushings complement the Dodge line, with each having success in different application segments and regions of the market,” says Payton. “Together we are certainly in a better position to effectively compete in the growing global market, and offer Baldor’s customers a broader line of product solutions.”

Baldor’s vice president in charge of the Maska integration, Rick Payton, describes Maska as a well-run and successful company that has made a significant amount of investment in equipment and technology in their plants. “Maska has focused on the fundamentals of cost reduction, high quality and great service to customers,” says Payton. “Because of their commitment to providing value, they will make an excellent addition to the Baldor family.”

Maska products, combined with Baldor’s line of mechanical power transmission products marketed under the Dodge® brand, positions


On September 2, 2008, Baldor Electric announced its acquisition of Poulies Maska, Inc. of Ste-Claire, Quebec. The company designs, manufactures and markets sheaves, bushings, couplings and related mechanical power transmission products.

Maska began in 1948 as a small, start-up machining workshop and has grown into a business with leading market share in Canada, and a significant presence in the United States. The company is also present in Latin America and Europe. In March of 2008, Maska opened a new manufacturing operation in China. This additional facility gives Baldor a second plant in China, helping the company continue plans for international growth.

Baldor ElECtriC aCquirEs maska powEr transmission BusinEss

Briefings


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Legislation Mandates Use of More Energy Efficient Motors by 2010…But Why Wait?

On December 19, 2007, President George Bush signed into law the Energy Independence

and Security Act (EISA) of 2007. This wide-ranging legislation covers a long list of energy issues, all with the intent of making America stronger, safer and cleaner for future generations. Perhaps more importantly for motor users, part of EISA addresses raising the efficiency levels of industrial electric

motors and expands the range of motors that are in question. The provisions, while representing a very small section of the Act’s 822 pages, may eventually bring about a very large reduction in energy use. Why? Because electric motors account for over 25% of total U.S. energy use, and motorized equipment accounts for 64% of the electricity U.S. manufacturers consume. It follows then,

that if the efficiency of those motors were raised by even a few percentage points, the savings in kilowatt-hours and in dollars, could be enormous. EISA will go into effect on December 19, 2010 and will apply to motors manufactured after that date. As mandated by EISA, the efficiency of 1 through 200 HP general purpose motors, currently covered by the Energy Policy Act (EPAct) of 1992, will change

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from NEMA MG-1, Table 12-11 Energy Efficient to Table 12-12 NEMA Premium® Efficient.

Motors 1 through 200 HP that were not previously covered by EPAct, such as C-face less base, close-coupled pump motors, vertical pump motors and Design C motors, will comply with NEMA MG-1, Table 12-11 Energy Efficient levels.

Additionally, 201 through 500 HP motors, previously not addressed, will comply with NEMA MG-1, Table 12-11 Energy Efficient levels.

While the new act doesn’t take effect until 2010, the question is why wait? With rising energy costs, it is wise to upgrade to the premium efficient designs and begin taking advantage of energy savings now. Evaluating the motor’s life cycle cost, rather than just the purchase price, may help make the decision easier.

The purchase price of an industrial motor is only about 2% of what users ultimately spend. Energy accounts for 97% of the total expense. While the initial purchase price may be higher, the added efficiency will recover the costs within 6 to 12 months. The savings in electricity will continue year-after-year over the next 15 to 20 years of the life of the motor.

Baldor•Reliance® premium efficient Super-E® motors meet or exceed the standards set by EISA. These motors are in-stock and available from Baldor distributors across the United States. Custom Super-E designs are also

available through 15,000 HP. Don’t wait until premium efficient motors are mandated in 2010. Upgrading sooner rather than later means that these efficient motors will return your investment by the time the new Act takes effect.

For more information, go to our website at www.baldor.com and take advantage of the Baldor Energy Saving Tool, BE$T, to calculate the potential savings that can be achieved by choosing premium efficient motors.

Above: Baldor's Super-E motor on an industrial mixer. Baldor introduced the Super-E premium efficient line in 1983.

Energy 97.3% Initial Purchase 2%One Rewind 0.7%

lifECyClE Cost of an industrial aC ElECtriC motor

The Secret is Out…The Secret is Out…

The Secret is Out…

In 1908, the year Henry Ford developed the first Model T automobile, A.J. Bush, along with

his sons, started Bush Brothers & Company as a tomato cannery. One-hundred years and three generations later the company, still family owned and operated, is the largest manufacturer of prepared beans in the country.

The company captured the baked bean market after launching the “Secret Family Recipe” advertising campaign in 1995. The television commercials feature Jay Bush and his canine companion Duke, a less than trustworthy guardian of the secret family recipe. Today the company produces more than 40 products, including their famous baked beans, which are marketed under the “Bush’s Best” brand name.

The majority of the company’s production comes from its Chestnut Hill, Tennessee facility. The plant produces millions of cans per week in a state-of-the-art facility that underwent a complete overhaul in 2004.

Baldor Products are a Key

Ingredient in Bush’s Best

Production Success

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Baldor•Reliance motors and Dodge TIGEAR-2 reducers are used on high-speed can conveyors throughout the Bush Bean facility. The reasons are clear for the maintenance team - the products perform under extreme conditions with little or no maintenance.

Choosing the Best Products to Produce the Best Beans Michael Rife, the plant’s maintenance planner and buyer, was a member of the design team that helped plan and implement the plant expansion project at the Chestnut Hill facility. One of team’s responsibilities was to find the best motors, gearboxes and bearings to use throughout the new facility. “We had the opportunity to travel around the country, visiting the best plants in all types of industries,” says Rife. “After our research, it was clear to us that if we wanted our plant to be among the best, we needed to specify Baldor•Reliance and Dodge products.”

Rife says the team also understood the value of making a product selection based on the total cost of ownership, not just focusing on the purchase price. “We know that you get what you pay for, and sometimes trying to save a buck up front will cost you so much more in the long run,” says Rife. “We wanted Baldor•Reliance and Dodge products because we knew these products would provide long term performance despite the demanding high speed applications and the harsh washdown conditions.”

Rife and his team have not been disappointed. Even as the plant continues to expand production to meet the growing demand for Bush’s Best, the motors, gear reducers and bearings are still performing. “We chose products based on what we felt was a good TCO strategy,” explains Rife. “It’s a nice feeling to be able to look back and know that we made the right choices.”

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"We wanted Baldor•Reliance® and Dodge® products because we knew these products would provide long term performance despite the demanding high

speed applications and the harsh washdown conditions."

Michael Rife, maintenance planner and buyer, Bush Beans

You'll find a variety of Baldor•Reliance motors throughout the Bush Bean plant, including this Standard E® Washdown Duty motor running the blancher. The plant has also chosen to install Dodge E-Z KLEEN bearings on all the conveyors.

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Another reason for their success, according to Rife, has come from choosing the correct style of product for a particular application. That’s why, he says, you’ll find a variety of Baldor•Reliance motors throughout the plant, from standard washdown duty, to paint-free and all-stainless steel motors. “When it comes to motors we get the performance and long life we want in all

these designs,” says Rife. “I have always been strong on Baldor•Reliance motors, I like them and I’m very happy with all of the units we have in the facility. Both inside and out, it’s just a better motor, it lasts and that’s exactly what we are looking for.”

Maintenance free is another reason why Rife is satisfied with the product choices

they have made. “I like the Dodge TIGEAR-2™ reducers because I don’t need to change the oil – the product comes with the oil already in it and all I have to do is take it out of the box and put it on,” explains Rife. “They’ll run forever and the lack of required maintenance on this product saves me a lot of time.”

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In addition to no maintenance, Rife also says that TIGEAR-2 reducers can handle the harsh working conditions. “These units run in a corrosive environment,” says Rife. “There is the bean juice, the cleaning chemicals, and the high pressure washdown – it’s all very tough on these products. But we have very good luck with them.”

The bearing of choice in the plant is the Dodge E-Z KLEEN®. “We chose the polymer-housed ball bearings because they can take the washdown and still perform and look good,” comments Rife. “We do try to take care of them with a good vibration analysis program, but this is a very good product and we just don’t lose bearings.”

Rife feels so strongly about these products that he continues to ask OEMs to use Baldor•Reliance and Dodge products on equipment being built for this plant. “Based on my 33 years of experience in this industry, I feel really good about the motors and mechanical products that we use and I plan on sticking with them,” says Rife. They are easy to install, easy to maintain and they last. I’ve been doing this a long time and have seen these products perform – I’ve got no problem recommending these products to anyone else.”

Above and Left: Baldor•Reliance stainless motors, Dodge TIGEAR-2 E-Z KLEEN reducers, and Dodge E-Z KLEEN stainless bearings are designed to offer superior long-term performance, even in the toughest environments with regular high-pressure sanitizing.

Right: Dodge E-Z KLEEN polymer-housed ball bearings are the standard in the Bush plant. These bearings feature a corrosion resistant insert, and a solid polymer housing with no cavities or fillings to trap contaminants. An active antimicrobial agent in the polymer prevents fungal and bacterial growth.


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Feel the DifferenceFeel the Difference

Feel the Difference

Feel the Difference

Feel the Difference


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Eric Clapton, Paul Simon, Jimmy Buffett and Paul McCartney: these are just a few of the

musicians who swear by a Martin Guitar. Since 1883, C.F. Martin & Co® has defined the highest standard of design, tone, and quality for the American acoustic guitar.

Today’s Martin guitars are created through a unique marriage of impeccable hand craftsmanship and state-of-the-art technology. The company’s goal is to continuously improve the more than 300 steps

required to complete one Martin guitar. Their latest project focused on a piece that impacts the action and the playability of the instrument; the fret board.

This piece of wood is what the musician feels as their hand moves up and down the guitar. Martin engineering project manager, Fred Walters, says while it may be difficult to put into words how the board should feel, he does know that the more accurate they can make the radius of this wooden piece, the better it is for the artist.

“Our challenge has always been to efficiently produce fret boards with a consistent radius, while maintaining the proper taper of the board,” says Walters. “The manually operated swing sander we used made it difficult to create the flatness that we needed, board after board. This meant re-working pieces on the machine and then hand sanding the wood to eliminate the inconsistencies.”

Walters wanted a new fully automated heavy machine that would have two sanding belts instead of just one, so pieces could be sanded with both coarse

The custom automated swing sander efficiently produces fret boards with a consistent radius, while maintaining the proper taper of the board. In the past, 43% of the boards had to be re-worked. This machine has virtually cut out the need for any hand sanding.


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and fine paper. He believed the key to sanding a perfect board was to smoothly feed the wood across the width of the entire belt, instead of the old method of sanding in one position, which clogged the belts.

Walters asked a local machine builder and systems integrator, Brian Rasley of Rasley Enterprises, to build Martin a new swing sander. “I started the project by asking lots of questions and watching the operator using the existing machine,” says Rasley. “I actually came back several times to observe how they were picking up parts and how the machine was running. Based on all this information, I created a design.”

When it came time to select the motion control products required to run the machine, Rasley says it was clear that Martin had a preference for Baldor

products. “During my visits to the plant I saw that Martin was using a lot of Baldor motors, and I always try to build my machines with the products the customer has had success with,” says Rasley. “Of course I’m also very familiar with Baldor, and based on my experience, I know Baldor manufactures robust products that get the job done.”

Walters didn’t hesitate to agree with Rasley’s recommendation. “We have always had good luck with the Baldor products installed in our plant,” says Walters. “Because these products have performed well and have never let us down, we felt very comfortable with this choice. Plus, we have always been able to count on Baldor for all the technical support that we needed, and I’m confident that when we need help in the future, we will continue to get that same support.”

Above: Two Baldor BSM servo motors, located below the sanding belts, are used to raise the belts after the work piece has moved across the sanding surface.

Above: This piece of wood is what the musician feels as their hand moves up and down the guitar. The more accurate Martin Guitar can make the radius of this wooden piece, the better it is for the artist.

Working closely with Baldor applications experts, the two companies conceived a motion control architecture that employs six axes of motion to automate the sanding process. Two vector motors power the rough and smooth sanding belts. Two servo motor axes are used to raise the belts after the work piece has moved across the sanding surface. Finally, the swing-arm jig that holds the fret board is powered by two axes of motion: a servo motor to swing the fret board in an arc, plus a linear motion axis that moves the swinging arm across the sanding belts. Products were then integrated into a real-time system using Baldor’s new Powerlink Ethernet-compatible network.

The electrical architecture of the machine is based on Baldor’s NextMove® e100 Powerlink compatible machine controller. This controls all six axes of movement: four via Powerlink connections to Baldor’s MicroFlex®

e100 motor drives, as well as stop/start and speed control of the two sanding belt axes that are controlled by Baldor H2® AC drives and vector motors. The rotary axes are driven by Baldor’s BSM servo motors.

Programming the system was also accomplished using Baldor’s Mint® development environment for Powerlink. “The Mint software is very robust, and very flexible because of its open architecture,” says Rasley. “More than that, Baldor is also so easy to work with, because not only do they provide the software, they also provide technical support that is superior, and provide software updates.”

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Right: Baldor’s NextMove e100 Powerlink compatible machine controller is considered the brains of the machine. It controls all six axes of movement, four of them via Powerlink connections to Baldor’s MicroFlex e100 motor drives located in this same panel.

Above: Baldor’s touch screen human-machine interface (HMI) is user friendly and makes it easy for the operator to run the machine. It’s been designed so the operator can quickly see all the information required to program the sander for the desired thickness of the board.

According to Walters, the Baldor touch screen human-machine interface (HMI) makes it easy for the operators to run the machine. “It’s very operator friendly and simple to use,” says Walters. “The operator uses the screen to program the sander for the desired thickness of the board. It’s been designed for the operator to quickly see all the information that is necessary.”

After more than six months of operation, Walters calls the project a success. “This machine is so accurate that it has virtually cut out the need for any hand sanding,” says Walters. “We used to have a 43 percent re-work

rate. Today that rate is down to three percent, and we think we can get that number lower.”

Rasley is equally pleased with the results. “Without a shadow of a doubt, this machine will last a long time and will continue to produce quality parts,” says Rasley. “We are using the best products, but more importantly, Baldor is willing to stand behind their products and provide excellent technical support. Baldor motion control experts have helped me understand what I needed to do, and that has made a real difference in the success of this project.”

While the statistics certainly point to success, perhaps the best measure of how the equipment has performed

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"We have always been able to count on Baldor for all the technical support that we needed, and I'm confident that when we need help in the future, we will continue to get that same support."

Fred Walters, engineering project manager, Martin Guitar

Above: The linear motion is the most critical of the axes and for this task, Baldor suggested using a linear motor with a “cog free” action. A special layout of the magnetic elements of this motor eliminates the tiny ripples of movement that can take place as the motor transitions between magnetic poles, providing ultra-smooth action.

should come from the craftspeople that string, inspect, and play the guitar before it leaves the factory. “We are getting nothing but compliments,” says Walters. “These employees are telling us that because the radius of the fret board is accurate and consistent, it’s easier for them to do the final set up of the guitar. They say they can “feel” the difference. It’s a good sign that others in the plant are noticing – we think that means we have done a good job.”

We want to to recognize Kaman Industrial Technologies for their support of Baldor products at Martin Guitar over the past 15 years.

These roller mills, the machines that grind wheat into flour, are critical pieces of equipment at Horizon Milling. A little over four years ago they began looking for a better bearing solution for the roller mills, seeking a product that would offer long lasting performance, plus be easy to install and remove. They found what they were looking for with Dodge IMPERIAL bearings.

Even before the wheel was invented, a revolutionary technology had been discovered:

the production of flour. The realization that indigestible seeds ground into nourishing dust steered the history and fate of man. Flour and bread are inseparably bound up with human civilization, and our dependence on this product continues today, as flour is the daily food of millions. Today’s modern mills work hard to meet the growing demand for flour, and many of them are investing in equipment to improve the process and maximize out-put, while containing costs. That’s the case at Horizon Milling, a Cargill Foods Affiliate mill located in Albany, New York. This facility produces nearly 2.3 million pounds of flour a day. A little over four years ago they began to

focus on roll stands and finding a better bearing to use on these critical pieces of equipment. Roll stands, sometimes called roller mills, are the machines that grind the wheat into flour. Basically, grain is fed between pairs of rotating hardened steel rollers. Each time the material passes between a pair of rollers, the resulting milled stock is run through a sifter, before it moves on to the next milling or until the desired consistency is achieved. Over the years roll stands have undergone many bearing modernizations or conversions, from sleeve bearings to a variety of roller bearings. The Albany mill had progressed to using an open-style roller bearing, but this bearing was clearly not the solution. Keith Lochner, head

miller and 30 year veteran of the facility, explains that because these bearings have to be hand-packed with grease in the dusty mill environment, with product leaking from the roll stands into the bearings, contamination is unavoidable. The result is too many bearings were failing prematurely. “I would estimate that we had two or three bearings a month that would fail,” says Lochner. “Not only was there the cost of replacing these bearings, it was also time consuming. When these bearings failed, they would seize-up on the roll and they were very, very difficult to get off.” They faced the same situation during regularly scheduled roll changes. Lochner explains that corrugated rolls are frequently removed so they can be

Switching to Dodge® IMPERIAL™ Bearings Helps Horizon Milling Grind Out The Savings

Switching to Dodge® IMPERIAL™ Bearings Helps Horizon Milling Grind Out

The Savings


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re-furbished, but he says to get the rolls out, you have to take off four bearings. “Again, these bearings just wouldn’t come off,” says Lochner. “We would have to pound them off, cut them off, or break them off. Of course these bearings would have to be scrapped, and that meant we were throwing out approximately 16 bearings a month.” When the local Motion Industries branch, Baldor’s distributor partner servicing the location, delivered two Dodge IMPERIAL bearings to be tested in the application, the mill was more than willing to give them a try. With nothing to lose, the mill installed the IMPERIAL inserts and let them run for a couple of months to see how they would perform. It didn’t take long before they knew they had found the solution they had been searching for. Nearly four years have passed since that first trial period, and Lochner reports that they have now installed more than 400 IMPERIAL bearings. From where Lochner stands, it couldn’t be more of a success. “I don’t have to track or worry about failures any longer,” reports Lochner. “Because these bearings are assembled at the factory and are already lubricated, we don’t have the issue of contamination when we install them. Plus they have a sealing system that helps keep the dust out. It all means that these bearings last.” Not only are the IMPERIAL bearings performing beyond expectations, they have also provided the easy-on, easy-off solution the mill had been searching for. “These bearings just come right off,” says Lochner. “In fact, it’s so much easier than before that we are saving a lot of time. The roll changes are quicker now and we can keep up with our schedule, even when the plant is running at peak capacity.” Another benefit, according to Ted Piel, the mills assistant facility manager, has been creating a safer work environment.

Above: This sequence of photos, from top to bottom, illustrates some of the simple steps involved in the removal of the Dodge IMPERIAL bearing. In the past, employees had to pound bearings off, cut them off or break them off, damaging the shaft and destroying the bearing. Today, IMPERIAL bearings are not only providing the easy-on, easy-off solution for the mill, but they are lasting years longer than the previous bearings.


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“The safety factor in making this change is huge,” claims Piel. “Remember that it took a lot of force to use a 15 pound tube or a sledge hammer to break the old bearings off. And while no one was ever seriously injured in the process, if we can use a product to prevent accidents, that’s what we want to do.”

The ease of removal has added up to one more benefit for the mill; saving money. Lochner says because the IMPERIAL bearings come off the shaft so easily, they can re-use the bearings again and again. “The biggest benefit to us has been the cost savings,” explains Lochner. “Remember that in the past we had to scrap the bearings, but not anymore. We have used bearings up to five times so far and that means we have gotten about four years out them.”

The Motion Industries branch in Albany has documented the actual savings achieved by switching to Dodge IMPERIAL bearings. According to a recent report that tracked bearing usage, the mill has saved $240,000 in product cost over the past three years. “The cost savings is the big story,” claims Lochner. “In the past, bearings would only last about a year and a half, but today the Dodge IMPERIAL bearings are lasting four years and running. That’s added up to tremendous savings for us, and that’s what it’s all about.”

“These bearings just come right off. In fact, it's so much easier than before that we are saving a lot of time.”

Keith Lochner, head miller, Horizon Milling

Above: The IMPERIAL bearing slides off the shaft so easily, the mill can re-use the bearings again and again, saving them $240,000 in product cost over the past three years.

Corrugated steel rollers are frequently removed so they can be re-furbished, but to get the rolls out, you first have to take off four bearings. By switching to Dodge IMPERIAL bearings the roll changes are fast and easy, saving the mill a lot of time.


New Drive System Package from Baldor

New Drive System Package from Baldor


Offers Mining Operations A Offers Mining Operations A

Complete SolutionComplete Solution

Anticipating the needs of mine operators who are increasing production to meet growing

demand, Baldor has introduced a complete drive system package that is powerful enough to drive the largest and longest conveyors.

The package features the new 2,500 K CST (Controlled Start Transmission), 2,500 HP Baldor•Reliance® motor, an optional 3,150 pound fly-wheel, and high and low-speed couplings with guards. The system is completely assembled at the factory on a heavy duty base and undergoes full speed range certification prior to shipment. This drive system can be used as a single unit, or in combination with several units as required by the application.


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This new offering is ideal for mining operations that want to operate larger conveyors, or mines that are shifting away from truck haulage to more efficient conveyor systems as the primary method to move material.

The new Dodge 2,500 K CST is the highest capacity CST manufactured with a rating of 3,500 in-lbs of torque. This large planetary gear reducer provides more power from enhanced gear tooth geometry, resulting in more torque for hard-to-start loads.

The controlled start provided by the CST is unsurpassed in accelerating heavily loaded conveyors, eliminating

belt shock waves, and extending conveyor belt life. This reduces the need for maintenance on other system components like couplings, bearings, shafts, gears, and keys. The new product also includes a state-of-the art filtration system providing longer time between oil changes, which reduces maintenance costs.

The Baldor•Reliance motor, pictured in this article, is a totally enclosed air-to-air cooled 2,500 HP motor. This motor is built for severe duty mining applications and includes sensors for monitoring bearing vibration, bearing temperature, and winding temperature. It also includes Inpro® seals and a triple

A clutch pack assembly is being installed in a 2,500 K CST. This is the primary mechanism for the soft start and control operation of the product.

VPI (vacuum pressure impregnation) process. All Baldor•Reliance motors can be customized to meet the specific needs of any application.

Products Plus Industry Expertise

Beyond quality products, Baldor provides customers with engineering expertise from a mining-focused industry team with years of experience. This team helps customers optimize the design of their system, ensuring that it is balanced and well matched.

In addition to application and system design work, Baldor also offers on-site commissioning of the drive system


features

Above: A technician is installing the initial reduction gear assemblies into the CST housing.

for proper starting characteristics, optimization of load sharing, and verification of the built-in equipment protection systems. Other services include providing training for the operators and maintenance teams. By choosing Baldor, end-users also benefit by having one point of contact when they have questions or need help.

Baldor designs, manufactures and assembles complete drive systems including base frame, CST, motor, couplings, pulleys, bearings and controls. The powerful combination of Baldor’s industry expertise and superior products guarantees that mining customers get a complete solution that is unmatched in the industry.

The new Dodge 2,500 K CST is the highest capacity CST manufactured with a rating of 3,500 in-lbs of torque. This large planetary gear reducer provides more power from enhanced gear tooth geometry, resulting in more torque for hard-to-start loads. The new product also includes a state-of-the-art filtration system providing longer time between oil changes, which reduces maintenance costs.


features

Sapphire Energy Recovery, with locations in four major regions of the U.K., operates high-throughput tire shredding machines that create chips used as an alternative to coal in cement manufacturing.

After shredding, chips are graded for size by a classifier with 36 sets of bearings.

However, the classifier shafts' set-screw style bearings were being damaged by fine metal wires in the tires, and by water used for cooling. As a result, they typically only lasted about six months.

In addition, changing these bearings could take nearly two hours per bearing. Corrosion sometimes meant that the bearings had to be loosened by heat, and in some cases the whole shaft had to be replaced. Solving these issues became a priority for Sapphire's Reliability Manager Andy Booth. With advice from the local Dodge distributor, Bearing Transmission & Pneumatics, Booth decided to try an adapter style ball bearing from Baldor, called Dodge GRIP TIGHT.

The adapter of this bearing is press fit to the shaft for full concentric contact, eliminating fretting corrosion and shaft damage. The Dodge GRIP TIGHT also features a patented pull/push adapter system, making it easy to remove the bearing.

After nearly two years, GRIP TIGHT bearings have performed up to their reputation – changeovers are easy and predictable, with no shaft damage. Sapphire also discovered an additional benefit; the

bearings are lasting at least twice as long as the previous set screw types.

"The aggressive nature of tire shredding meant that repairing these machines was taking up far too much of our time, and reducing our productivity," says Andy Booth. "GRIP TIGHT bearings have given us back predictability of maintenance, with the welcome bonus of much longer life, protecting some of our company's most crucial assets. Our operational team now has the time to be more

Baldor’s Dodge® GRIP TIGHT® Bearings Double Uptime and Cut Costs for United Kingdom’s Leading Tire Recycler

proactive, focusing its major efforts on preventive maintenance rather than breakdown maintenance."

"In our line of work, we tend to see a lot of bearing failures, and we've come to regard the Dodge GRIP TIGHT as a genuine problem solver," says Edward Fielding of Bearing Transmission & Pneumatics. "Although the major requirement was to simplify changeover, this bearing also manages to survive much longer in very hostile operating conditions."

Every Baldor generator set,

standard or custom, is designed

and engineered to meet the

individual needs of your application.

Whether it’s a 2,000 kW genset to

keep your industrial facility up and

running, or a 30 kW generator for

your remote agricultural needs,

Baldor has the right products to

meet your need.

Engineered to the highest

performance standards and built

with unmatched quality, Baldor

gensets give you the power you

need, when you want it.

baldor.com

©2008 Baldor Electric Company

Standby for Big Power

World HeadquartersP.O. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1) 479.646.4711, Fax (1) 479.648.5792, International Fax (1) 479.648.5895

www.baldor.com© Baldor Electric Company

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