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Malteurop North AmericaSelects Reliable Baldor Products for Malthouse Upgrade

Baldor•Reliance® Large AC MotorsInstalled Ten Years Ago at Holcim’s Holly Hill Plant Continue to Provide Reliable Service

solutionsm a g a z i n eA Publication Featuring Baldor Electric Company Products Number 9

Plus

Domtar's Marlboro Paper Mill

with Help from Baldor

Moves to AC Technology

Contents Number 9 Solutions Magazine Featuring Baldor•Reliance® & Baldor•Dodge® Products baldor.com

28 Baldor's Dodge® MagnaGear™ In-Stock Program

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 email smtraylor@baldor.com.

baldor.com

2 Briefings

4 Baldor•Reliance® Large AC Motors

10 Ten-Year Partnership Between Concept Machine & Design and Baldor is Labeled a Success

16 Domtar's Marlboro Paper Mill Moves to AC Technology with Help from Baldor

22 Malteurop North America Selects Reliable Baldor Products for Malthouse Upgrade

Cover: PG 16

Installed Ten Years Ago at Holcim's Holly Hill Plant Continue to Provide Reliable Performance

Gets Barge Conveyor Back Up and Running

The First Name in Power Transmission

• Unmatched Quality

• Superior Reliability

• Improved Uptime

• Quick Delivery

Baldor•Dodge® power transmission products offer reliable service and low maintenance to help reduce your total cost of ownership. Our innovative bearings, gearing and power transmission products have solved the toughest applications for over 125 years.

Our technical sales team can help you with the most challenging applications, and our worldwide distributor network ensures immediate delivery.

When it comes to PT solutions, Baldor•Dodge is the first name in power transmission.

baldor.com 479-646-4711

Contents Number 9 Solutions Magazine Featuring Baldor•Reliance® & Baldor•Dodge® Products baldor.com

28 Baldor's Dodge® MagnaGear™ In-Stock Program

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 email smtraylor@baldor.com.

baldor.com

2 Briefings

4 Baldor•Reliance® Large AC Motors

10 Ten-Year Partnership Between Concept Machine & Design and Baldor is Labeled a Success

16 Domtar's Marlboro Paper Mill Moves to AC Technology with Help from Baldor

22 Malteurop North America Selects Reliable Baldor Products for Malthouse Upgrade

Cover: PG 16

Installed Ten Years Ago at Holcim's Holly Hill Plant Continue to Provide Reliable Performance

Gets Barge Conveyor Back Up and Running

The First Name in Power Transmission

• Unmatched Quality

• Superior Reliability

• Improved Uptime

• Quick Delivery

Baldor•Dodge® power transmission products offer reliable service and low maintenance to help reduce your total cost of ownership. Our innovative bearings, gearing and power transmission products have solved the toughest applications for over 125 years.

Our technical sales team can help you with the most challenging applications, and our worldwide distributor network ensures immediate delivery.

When it comes to PT solutions, Baldor•Dodge is the first name in power transmission.

baldor.com 479-646-4711

Briefings

Number 9 | Solutions Magazine | 3

Briefings

2 | Solutions Magazine | Number 9

Baldor's dodge® PTPlace.com goes moBile

There’s a new mobile website for PTplace.com users that provides real-time, online inventory availability of Dodge power transmission products from a mobile device.

PTplace Mobile is easy to use and allows users to get detailed part information and pricing using the same log-in credentials as PTplace.com. A functionality called "Super search" also enables searching by description or partial part numbers. Currently the PTplace.com website serves over 20,000 distributor employees who track inventory and place orders more than 65,000 times a day. In the past, outside sales representatives retrieved critical information by relying on catalogs,

phone calls and emails. Today, with the new PTplace Mobile site, they have a quick and convenient way to access product details and check stock and pricing. The mobile site can be accessed by typing m.ptplace.com into the browser of any mobile device. PTplace.com is operated by CoLinx, LLC, an e-commerce and logistics service provider owned by five manufacturers.

Baldor Now offers comPleTe liNe of large ac moTors

The new Dodge Disc coupling, designed to meet the American Petroleum Institute (API) 610 specification, is the ideal solution for pumping applications in the oil and gas industry.

The Dodge Disc coupling utilizes the newest generation of disc geometry, which minimizes disc stress during operation, and produces the highest misalignment and torque capability of any disc coupling on the market. (See details below.) These capabilities improve reliability and extend the overall life of the coupling.

This new coupling also allows users to lower costs by offering a large hub option that increases the max bore capability in applications where the coupling size is driven by the shaft diameter instead of the torque requirement.

Additionally, the Dodge Disc coupling offers all the advantages of a metallic coupling, including a large bore

Baldor's New dodge® disc couPliNg eNgiNeered for The oil aNd gas iNdusTry –

offeriNg imProved reliaBiliTy, iNcreased ProducTiviTy aNd lower cosTs

range, high speed capabilities, high torque ratings and precision balancing. However, because the Dodge product does not have relative movement between mating surfaces, there is no need for lubrication, resulting in reduced maintenance and increased productivity.

ABB and Baldor•Reliance® motors are recognized by the oil and gas industry

While competitors utilize a disc geometry that features a single scalloped design, the new Dodge Disc coupling utilizes the newest generation of disc geometry – a dual scalloped design. This new design offers an even distribution of material along the “axis of bolt center,” which drastically reduces the number of high stress areas within the disc. The peak stress in the Dodge Disc geometry is 13% less than the competitor’s geometry, resulting in an average of double the torque capacity. Additionally, an even distribution of material along the “axis of bolt center” maximizes misalignment capability and offers up to three times the misalignment of the leading competitor. Industry-leading torque ratings and misalignment capability will ultimately lead to longer coupling life and improved reliability.

Baldor now offers customers in North America access to the most complete line of large AC motors in the world from a single, local sales team.

Baldor•Reliance® stock and custom motors are available up to 15,000 HP, while ABB induction and synchronous motors are available up to 100,000 HP. This large AC motor offering includes both NEMA and IEC configurations, assuring customers that they will get the motor that meets frame, enclosure and duty cycle standards for any application, anywhere in the world. Every large AC motor is designed and built for superior reliability, energy savings and rugged performance.

Local presence, combined with a global technical field sales support team serving both Baldor and ABB, means customers will receive the best service and support in the industry.

as industry-leading products, offering

superior performance and reliability. Now these users can get the same level of quality from an entire pump driver package by incorporating the Dodge Disc coupling into all pumping applications.

dodge disc geomeTry makes The differeNce

Briefings

Number 9 | Solutions Magazine | 3

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2 | Solutions Magazine | Number 9

Baldor's dodge® PTPlace.com goes moBile

There’s a new mobile website for PTplace.com users that provides real-time, online inventory availability of Dodge power transmission products from a mobile device.

PTplace Mobile is easy to use and allows users to get detailed part information and pricing using the same log-in credentials as PTplace.com. A functionality called "Super search" also enables searching by description or partial part numbers. Currently the PTplace.com website serves over 20,000 distributor employees who track inventory and place orders more than 65,000 times a day. In the past, outside sales representatives retrieved critical information by relying on catalogs,

phone calls and emails. Today, with the new PTplace Mobile site, they have a quick and convenient way to access product details and check stock and pricing. The mobile site can be accessed by typing m.ptplace.com into the browser of any mobile device. PTplace.com is operated by CoLinx, LLC, an e-commerce and logistics service provider owned by five manufacturers.

Baldor Now offers comPleTe liNe of large ac moTors

The new Dodge Disc coupling, designed to meet the American Petroleum Institute (API) 610 specification, is the ideal solution for pumping applications in the oil and gas industry.

The Dodge Disc coupling utilizes the newest generation of disc geometry, which minimizes disc stress during operation, and produces the highest misalignment and torque capability of any disc coupling on the market. (See details below.) These capabilities improve reliability and extend the overall life of the coupling.

This new coupling also allows users to lower costs by offering a large hub option that increases the max bore capability in applications where the coupling size is driven by the shaft diameter instead of the torque requirement.

Additionally, the Dodge Disc coupling offers all the advantages of a metallic coupling, including a large bore

Baldor's New dodge® disc couPliNg eNgiNeered for The oil aNd gas iNdusTry –

offeriNg imProved reliaBiliTy, iNcreased ProducTiviTy aNd lower cosTs

range, high speed capabilities, high torque ratings and precision balancing. However, because the Dodge product does not have relative movement between mating surfaces, there is no need for lubrication, resulting in reduced maintenance and increased productivity.

ABB and Baldor•Reliance® motors are recognized by the oil and gas industry

While competitors utilize a disc geometry that features a single scalloped design, the new Dodge Disc coupling utilizes the newest generation of disc geometry – a dual scalloped design. This new design offers an even distribution of material along the “axis of bolt center,” which drastically reduces the number of high stress areas within the disc. The peak stress in the Dodge Disc geometry is 13% less than the competitor’s geometry, resulting in an average of double the torque capacity. Additionally, an even distribution of material along the “axis of bolt center” maximizes misalignment capability and offers up to three times the misalignment of the leading competitor. Industry-leading torque ratings and misalignment capability will ultimately lead to longer coupling life and improved reliability.

Baldor now offers customers in North America access to the most complete line of large AC motors in the world from a single, local sales team.

Baldor•Reliance® stock and custom motors are available up to 15,000 HP, while ABB induction and synchronous motors are available up to 100,000 HP. This large AC motor offering includes both NEMA and IEC configurations, assuring customers that they will get the motor that meets frame, enclosure and duty cycle standards for any application, anywhere in the world. Every large AC motor is designed and built for superior reliability, energy savings and rugged performance.

Local presence, combined with a global technical field sales support team serving both Baldor and ABB, means customers will receive the best service and support in the industry.

as industry-leading products, offering

superior performance and reliability. Now these users can get the same level of quality from an entire pump driver package by incorporating the Dodge Disc coupling into all pumping applications.

dodge disc geomeTry makes The differeNce

Briefings

Number 9 | Solutions Magazine | 5

Briefings

4 | Solutions Magazine | Number 9

Continue to Provide Reliable Performance

at Holcim's Holly Hill Plant

Baldor•Reliance® Large AC Motors Installed Ten Years Ago

Briefings

Number 9 | Solutions Magazine | 5

Briefings

4 | Solutions Magazine | Number 9

Continue to Provide Reliable Performance

at Holcim's Holly Hill Plant

Baldor•Reliance® Large AC Motors Installed Ten Years Ago

Number 9 | Solutions Magazine | 7

Featuresfeatures

6 | Solutions Magazine | Number 9

Holcim (US) Inc. is a subsidiary of Holcim Ltd and one of the nation’s leading manufacturers and suppliers of cement. The company operates 12 manufacturing plants in the United States, including the facility in Holly Hill, South Carolina.

Cement has been produced at this location since 1966, but a little over 10 years ago, work began to construct a new energy-efficient plant on the Holly Hill site.

In addition to increasing the plant’s overall efficiency, the company built the new plant with reliability in mind in order to reduce maintenance costs. The new mill is twice the size of the old facility with a capacity of 2.2 million metric tons per year.

Because large AC motors are used in the most critical applications, company officials chose to install Baldor•Reliance large AC motors. After more than nine years in operation, the team that’s responsible for keeping the plant up and running says the company made the right choice.

Both Allen Davis and David Berry, electrical instrumentation technicians, worked at the old plant and helped commission the new facility. Davis says maintenance costs were high at the old plant because of constantly failing motors. But over the past 10 years, that hasn’t been the case because the Baldor•Reliance motors have been reliable.

“We routinely test our large AC motors, and I’ve been impressed with the results,” says Davis. “When we meg these motors, we see very high resistance, which is good because we know we don’t have to worry about the motors shorting out. I’m very pleased with these motors because they just run and run, and we sleep better knowing these motors test well.”

This 2,700 HP WPII Baldor•Reliance motor operates the main bag house dust collector. The captured particulates are recycled back into the cement-making process.

The dilution air fan is powered by a 700 HP WPII Baldor•Reliance motor. This fan pulls heat from the clinker cooler to help dry raw materials in the raw mill using the hot gas generator.

An 800 HP Baldor•Reliance TEFC (blower assist cooled) motor is used on the coal mill drive that grinds the coal used to fire the kiln.

Number 9 | Solutions Magazine | 7

Featuresfeatures

6 | Solutions Magazine | Number 9

Holcim (US) Inc. is a subsidiary of Holcim Ltd and one of the nation’s leading manufacturers and suppliers of cement. The company operates 12 manufacturing plants in the United States, including the facility in Holly Hill, South Carolina.

Cement has been produced at this location since 1966, but a little over 10 years ago, work began to construct a new energy-efficient plant on the Holly Hill site.

In addition to increasing the plant’s overall efficiency, the company built the new plant with reliability in mind in order to reduce maintenance costs. The new mill is twice the size of the old facility with a capacity of 2.2 million metric tons per year.

Because large AC motors are used in the most critical applications, company officials chose to install Baldor•Reliance large AC motors. After more than nine years in operation, the team that’s responsible for keeping the plant up and running says the company made the right choice.

Both Allen Davis and David Berry, electrical instrumentation technicians, worked at the old plant and helped commission the new facility. Davis says maintenance costs were high at the old plant because of constantly failing motors. But over the past 10 years, that hasn’t been the case because the Baldor•Reliance motors have been reliable.

“We routinely test our large AC motors, and I’ve been impressed with the results,” says Davis. “When we meg these motors, we see very high resistance, which is good because we know we don’t have to worry about the motors shorting out. I’m very pleased with these motors because they just run and run, and we sleep better knowing these motors test well.”

This 2,700 HP WPII Baldor•Reliance motor operates the main bag house dust collector. The captured particulates are recycled back into the cement-making process.

The dilution air fan is powered by a 700 HP WPII Baldor•Reliance motor. This fan pulls heat from the clinker cooler to help dry raw materials in the raw mill using the hot gas generator.

An 800 HP Baldor•Reliance TEFC (blower assist cooled) motor is used on the coal mill drive that grinds the coal used to fire the kiln.

Number 9 | Solutions Magazine | 9

Features

8 | Solutions Magazine | Number 9

Features

The kiln-induced draft (ID) fan is powered by a 5,000 HP WPII Baldor•Reliance large AC motor. The ID fan is a central element in the clinker production process as raw meal is fed into the kiln and sintered.

A Baldor•Reliance 1,200 HP WPII (blower assist cooled) motor rotates the kiln about one to three revolutions per minute. Raw meal in the kiln is heated to about 2,700 F to produce clinker, which is then cooled and ground into the gray powder known as Portland Cement.

Baldor•Dodge® Sleevoil® RTL hydrodynamic bearings can be found on fan applications throughout the Holly Hill plant. This bearing is an ideal choice because the liner design offers excellent radial and thrust load capacities and exceptional bearing life with minimal maintenance. This standard water-cooled unit is premachined for thermocouples, a vibration sensor, circulating oil and auxiliary seals to allow for monitoring and extra protection. Plant reliability engineer Enrique Reyes says that there have never been any issues with these bearings and that they only require maintenance once per year to drain and replace a small amount of oil. He says he doesn’t really worry about these bearings because they have never caused him any problems.

“These motors are so dependable the repair people no longer get any work from us, and that’s

a very good thing.”

Allen Davis, electrical instrumentation technician,

Holcim Holly Hill plant

Another aspect of their motor preventive-maintenance program is vibration analysis. Berry says monitoring and trending vibration helps identify potential problems, particularly with the rotor or stator, so corrective actions can be taken before failure. Considered a key indicator of health, the tests show the large AC motors throughout the plant are running well.

“Because vibration can tell you so much, we have brought in an outside third party to conduct on-line testing,” says Berry. “We have not seen any issues that would lead us to believe any of these motors need anything other than routine attention. I can’t think of anything that we have uncovered by doing this testing – and that’s a good thing.”

Throughout the facility you’ll find Baldor•Reliance large AC motors, ranging from 400 HP all the way to 5,000 HP, running critical applications. Because the plant is not designed for backup, losing any one of these motors would be catastrophic. But after more than nine years of trouble-free performance, Berry believes these motors are built to last.

“It may be hard to believe, but we haven’t had any problems with our large AC motors,” says Berry. “I know a lot of thought went into the selection of motors for our new plant, and today we can say they chose a good product. These big motors are very reliable, and by maintaining them the way we do, they will last for a very long time.”

For Davis, it’s also clear the right motor selection was made and credits its performance to quality windings and superior insulation systems. Davis says he and Berry remember the old days when they chased motors to keep the

plant running, but he’s happy to report that those days are long gone.

“There was a time when motor repair people lived at our plant,” says Davis. “A motor shop guy still stops by each

week asking if we have any motors to be repaired, and it’s a blessing for me to tell him no. These motors are so dependable the repair people no longer get any work from us, and that’s a very good thing.”

Number 9 | Solutions Magazine | 9

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The kiln-induced draft (ID) fan is powered by a 5,000 HP WPII Baldor•Reliance large AC motor. The ID fan is a central element in the clinker production process as raw meal is fed into the kiln and sintered.

A Baldor•Reliance 1,200 HP WPII (blower assist cooled) motor rotates the kiln about one to three revolutions per minute. Raw meal in the kiln is heated to about 2,700 F to produce clinker, which is then cooled and ground into the gray powder known as Portland Cement.

Baldor•Dodge® Sleevoil® RTL hydrodynamic bearings can be found on fan applications throughout the Holly Hill plant. This bearing is an ideal choice because the liner design offers excellent radial and thrust load capacities and exceptional bearing life with minimal maintenance. This standard water-cooled unit is premachined for thermocouples, a vibration sensor, circulating oil and auxiliary seals to allow for monitoring and extra protection. Plant reliability engineer Enrique Reyes says that there have never been any issues with these bearings and that they only require maintenance once per year to drain and replace a small amount of oil. He says he doesn’t really worry about these bearings because they have never caused him any problems.

“These motors are so dependable the repair people no longer get any work from us, and that’s

a very good thing.”

Allen Davis, electrical instrumentation technician,

Holcim Holly Hill plant

Another aspect of their motor preventive-maintenance program is vibration analysis. Berry says monitoring and trending vibration helps identify potential problems, particularly with the rotor or stator, so corrective actions can be taken before failure. Considered a key indicator of health, the tests show the large AC motors throughout the plant are running well.

“Because vibration can tell you so much, we have brought in an outside third party to conduct on-line testing,” says Berry. “We have not seen any issues that would lead us to believe any of these motors need anything other than routine attention. I can’t think of anything that we have uncovered by doing this testing – and that’s a good thing.”

Throughout the facility you’ll find Baldor•Reliance large AC motors, ranging from 400 HP all the way to 5,000 HP, running critical applications. Because the plant is not designed for backup, losing any one of these motors would be catastrophic. But after more than nine years of trouble-free performance, Berry believes these motors are built to last.

“It may be hard to believe, but we haven’t had any problems with our large AC motors,” says Berry. “I know a lot of thought went into the selection of motors for our new plant, and today we can say they chose a good product. These big motors are very reliable, and by maintaining them the way we do, they will last for a very long time.”

For Davis, it’s also clear the right motor selection was made and credits its performance to quality windings and superior insulation systems. Davis says he and Berry remember the old days when they chased motors to keep the

plant running, but he’s happy to report that those days are long gone.

“There was a time when motor repair people lived at our plant,” says Davis. “A motor shop guy still stops by each

week asking if we have any motors to be repaired, and it’s a blessing for me to tell him no. These motors are so dependable the repair people no longer get any work from us, and that’s a very good thing.”

Number 9 | Solutions Magazine | 1110 | Solutions Magazine | Number 9

FeaturesFeatures

Ten-Year Partnership

Labeled a Success Not only does James Turner build his own labeling equipment for his family-owned business that specializes in heat-transfer decoration, but he also founded a separate company – Concept Machine & Design –

that custom designs and manufactures heat transfer labeling equipment for the packaging industry. Whether it’s providing labeling services or providing innovative equipment, Turner’s businesses are known for quality. And he credits a portion of his success to his 10-year partnership with Baldor.

Number 9 | Solutions Magazine | 1110 | Solutions Magazine | Number 9

FeaturesFeatures

Ten-Year Partnership

Labeled a Success Not only does James Turner build his own labeling equipment for his family-owned business that specializes in heat-transfer decoration, but he also founded a separate company – Concept Machine & Design –

that custom designs and manufactures heat transfer labeling equipment for the packaging industry. Whether it’s providing labeling services or providing innovative equipment, Turner’s businesses are known for quality. And he credits a portion of his success to his 10-year partnership with Baldor.

Number 9 | Solutions Magazine | 13

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Features

That’s why when his company, based in Burlington, Kentucky, was awarded the contract to build 15 heat transfer labeling machines for a large food manufacturer, there was no doubt that Baldor motion control products would be used on these machines.

System integrator Steve Ziegler, with Zigtronics Inc., also has a long history working with Turner, Baldor and the Cincinnati district office. He was a part of this latest project from the beginning and says the machine the team designed is a very sophisticated piece of equipment that uses a heat-transfer process that labels three panels of a round container in one motion, instead of doing each panel individually.

“The container is moved into a nesting nozzle that grabs the container and indexes it to a specific mark putting the container into position,” explains Ziegler. “Next the label is applied using a heat process to apply the label on in a 3% stretch onto the container before it exits the machine. The label placement has to be plus or minus 1/32" at the part seam, and we rely on the Baldor equipment to maintain this position accuracy.”

The Baldor products selected to make sure that the motion, position and pressure are right every time include the NextMove® e100 motion controller, seven MicroFlex® e100s and seven servo motors. Ziegler says because the motion controller is an Ethernet Powerlink integrated hub, it communicates to each individual servo drive, creating seven axes of motion.

“The system is sophisticated in the way that all seven axes are moving at the same time to control the paper and wax label and the container,” says Ziegler. “The paper label itself is floating on a layer of wax, which is heated up just enough to get the wax to liquefy. Then, right at the point when we apply it to the container, we heat the adhesive up a little hotter so it adheres to the container.”

This high-speed labeling machine is designed for a unique heat-transfer decorating process for plastic containers. Baldor motion control products were selected because of the power, reliability and flexibility they provide. Coupled with Baldor’s Mint® easy-to-use programming language, the system captures, orients and presents containers to the labeling heads for accurate label placement.

Baldor’s NextMove e100 real-time Ethernet motion controller communicates with seven Baldor MicroFlex e100 servo drives to create seven axes of motion in this application. This digital solution reduces the wiring between the drives and the motion controller, improving set up time and increasing reliability. These products were selected because they are easy to install, and user-friendly, and they offer the precise performance required in this unique application.

Number 9 | Solutions Magazine | 13

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Features

That’s why when his company, based in Burlington, Kentucky, was awarded the contract to build 15 heat transfer labeling machines for a large food manufacturer, there was no doubt that Baldor motion control products would be used on these machines.

System integrator Steve Ziegler, with Zigtronics Inc., also has a long history working with Turner, Baldor and the Cincinnati district office. He was a part of this latest project from the beginning and says the machine the team designed is a very sophisticated piece of equipment that uses a heat-transfer process that labels three panels of a round container in one motion, instead of doing each panel individually.

“The container is moved into a nesting nozzle that grabs the container and indexes it to a specific mark putting the container into position,” explains Ziegler. “Next the label is applied using a heat process to apply the label on in a 3% stretch onto the container before it exits the machine. The label placement has to be plus or minus 1/32" at the part seam, and we rely on the Baldor equipment to maintain this position accuracy.”

The Baldor products selected to make sure that the motion, position and pressure are right every time include the NextMove® e100 motion controller, seven MicroFlex® e100s and seven servo motors. Ziegler says because the motion controller is an Ethernet Powerlink integrated hub, it communicates to each individual servo drive, creating seven axes of motion.

“The system is sophisticated in the way that all seven axes are moving at the same time to control the paper and wax label and the container,” says Ziegler. “The paper label itself is floating on a layer of wax, which is heated up just enough to get the wax to liquefy. Then, right at the point when we apply it to the container, we heat the adhesive up a little hotter so it adheres to the container.”

This high-speed labeling machine is designed for a unique heat-transfer decorating process for plastic containers. Baldor motion control products were selected because of the power, reliability and flexibility they provide. Coupled with Baldor’s Mint® easy-to-use programming language, the system captures, orients and presents containers to the labeling heads for accurate label placement.

Baldor’s NextMove e100 real-time Ethernet motion controller communicates with seven Baldor MicroFlex e100 servo drives to create seven axes of motion in this application. This digital solution reduces the wiring between the drives and the motion controller, improving set up time and increasing reliability. These products were selected because they are easy to install, and user-friendly, and they offer the precise performance required in this unique application.

Number 9 | Solutions Magazine | 15

Features Features

14 | Solutions Magazine | Number 9

Company officials say their long-term partnership with Baldor has helped them reach their goal of providing high-quality heat transfer labeling equipment that generates the fastest speed possible with the most accurate label placement. Here, a Concept Machine & Design employee is working on four of the seven Baldor BSM Series servo motors used on the machine. Designed for industrial applications, Baldor servo motors offer superior durability and proven reliability.

Baldor motion control products are programmed to provide the right feed, placement and pressure for the machine to apply heat transfer labels from a preprinted, continuous paper web to the container. This new equipment has helped the end user become more efficient by taking its scrap rate of 7% at 50 containers per minute to less than half of 1% at 60 containers per minute.

Turner Plastic Innovations, Inc., services the packaging industry with on-time, quality custom decorating. This labeling machine is using heat transfer technology to decorate caps for detergent bottles. With Baldor’s NextMove e100 real-time Ethernet motion controller and MicroFlex e100 servo drives, the machine runs 200 caps per minute. Company president James Turner says the machine has run for nearly five years with no failure. He says the Baldor equipment is reliable, and that’s why he continues to use these products on all the equipment he builds.

After more than two and a half years in operation, in what Turner describes as a harsh environment with high temperatures and high humidity, the machines have performed flawlessly with no failures. He says the customer was looking for a new machine that would help them increase productivity, and that’s just what’s happened.

“The customer wanted labeling equipment that would help reduce their scrap rate,” says Turner. “In the past, they had a scrap rate of 7% at 50 bottles a minute. With this new equipment, that rate has dropped to less than half of 1% at 60 bottles a minute, and the customer couldn’t be happier.”

As the system integrator, it’s Ziegler’s responsibility to install the equipment

at the customer site and get it up and running. He says what he likes about using Baldor motion control products is that he can design a complete machine that quickly drops into place, requiring nothing else but a connection to power and air. But more importantly, Zeigler

says he likes the way his customers can easily use the equipment.

“Within just a short amount of time, I can train the customer on how to use the products and the software because it’s all designed to be user friendly,” says

“Others have tried to get my business, but I continue to use Baldor motion control products

because it's a much easier package to work with, the products perform and they are reliable.”

Steve Ziegler president, Zigtronics Inc.

Ziegler. “Plus, Baldor offers the software for free and provides free upgrades via the Internet – that’s a huge benefit to both me and the customer. Others have tried to get my business, but I continue to use Baldor motion control products because it’s a much easier package to work with, the products perform, and they are reliable.”

Quick access to products is also a key reason Ziegler and Turner continue to partner with Baldor. They build a large amount of high-speed motion equipment for all types of applications and often have only a limited amount of time to get the machine built, installed and running. Turner says they count on Baldor to respond to their

requests quickly, and they’ve never been disappointed.

“Baldor keeps products stocked, and that kind of availability is so important to us,” says Turner. “Plus, we get fantastic support from sizing, product selection and training. Bottom line is that we get everything we want from Baldor – that’s why we have partnered with them for the past 10 years, and it’s why they will be a part of our future."

Baldor Motion is Changing…Introducing ABB MotionPlease note that the Baldor motion control products and servo drives featured in this story were installed prior to our transition to the ABB Motion brand. The products remain functionally unchanged, only the exterior color and logo have changed.

Number 9 | Solutions Magazine | 15

Features Features

14 | Solutions Magazine | Number 9

Company officials say their long-term partnership with Baldor has helped them reach their goal of providing high-quality heat transfer labeling equipment that generates the fastest speed possible with the most accurate label placement. Here, a Concept Machine & Design employee is working on four of the seven Baldor BSM Series servo motors used on the machine. Designed for industrial applications, Baldor servo motors offer superior durability and proven reliability.

Baldor motion control products are programmed to provide the right feed, placement and pressure for the machine to apply heat transfer labels from a preprinted, continuous paper web to the container. This new equipment has helped the end user become more efficient by taking its scrap rate of 7% at 50 containers per minute to less than half of 1% at 60 containers per minute.

Turner Plastic Innovations, Inc., services the packaging industry with on-time, quality custom decorating. This labeling machine is using heat transfer technology to decorate caps for detergent bottles. With Baldor’s NextMove e100 real-time Ethernet motion controller and MicroFlex e100 servo drives, the machine runs 200 caps per minute. Company president James Turner says the machine has run for nearly five years with no failure. He says the Baldor equipment is reliable, and that’s why he continues to use these products on all the equipment he builds.

After more than two and a half years in operation, in what Turner describes as a harsh environment with high temperatures and high humidity, the machines have performed flawlessly with no failures. He says the customer was looking for a new machine that would help them increase productivity, and that’s just what’s happened.

“The customer wanted labeling equipment that would help reduce their scrap rate,” says Turner. “In the past, they had a scrap rate of 7% at 50 bottles a minute. With this new equipment, that rate has dropped to less than half of 1% at 60 bottles a minute, and the customer couldn’t be happier.”

As the system integrator, it’s Ziegler’s responsibility to install the equipment

at the customer site and get it up and running. He says what he likes about using Baldor motion control products is that he can design a complete machine that quickly drops into place, requiring nothing else but a connection to power and air. But more importantly, Zeigler

says he likes the way his customers can easily use the equipment.

“Within just a short amount of time, I can train the customer on how to use the products and the software because it’s all designed to be user friendly,” says

“Others have tried to get my business, but I continue to use Baldor motion control products

because it's a much easier package to work with, the products perform and they are reliable.”

Steve Ziegler president, Zigtronics Inc.

Ziegler. “Plus, Baldor offers the software for free and provides free upgrades via the Internet – that’s a huge benefit to both me and the customer. Others have tried to get my business, but I continue to use Baldor motion control products because it’s a much easier package to work with, the products perform, and they are reliable.”

Quick access to products is also a key reason Ziegler and Turner continue to partner with Baldor. They build a large amount of high-speed motion equipment for all types of applications and often have only a limited amount of time to get the machine built, installed and running. Turner says they count on Baldor to respond to their

requests quickly, and they’ve never been disappointed.

“Baldor keeps products stocked, and that kind of availability is so important to us,” says Turner. “Plus, we get fantastic support from sizing, product selection and training. Bottom line is that we get everything we want from Baldor – that’s why we have partnered with them for the past 10 years, and it’s why they will be a part of our future."

Baldor Motion is Changing…Introducing ABB MotionPlease note that the Baldor motion control products and servo drives featured in this story were installed prior to our transition to the ABB Motion brand. The products remain functionally unchanged, only the exterior color and logo have changed.

Number 9 | Solutions Magazine | 1716 | Solutions Magazine | Number 9

Features Features

All the Baldor•Reliance large AC motors on the dryer drive line are variable speed, allowing the process to be slowed down or speeded up, depending on the grade of paper that is running.

Domtar's Marlboro Paper Mill

with Help from Baldor

Moves to AC Technology

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Features Features

All the Baldor•Reliance large AC motors on the dryer drive line are variable speed, allowing the process to be slowed down or speeded up, depending on the grade of paper that is running.

Domtar's Marlboro Paper Mill

with Help from Baldor

Moves to AC Technology

Features Features

The Marlboro paper mill, located in Bennettsville, South Carolina, was originally opened by Willamette in 1990 and became part of Domtar in 2007. With one pulp line and one paper machine, this mill has an annual paper production capacity of up to 389,000 tons.

Shortly after becoming a part of Domtar, mill officials determined that they needed to move the mill’s technology forward to be more in line

with the latest industry norm for paper mill applications.

That meant converting existing DC motors and drives to AC technology. The cost of rebuilding DC motors and the ongoing cost of brush maintenance also contributed to the decision to make the switch.

Bill Rogers, manufacturing services department manager at the Marlboro mill, led the effort to find not only

the right motors for the retrofit but also the right company to trust with this complex project. Rogers says they looked at a number of manufacturers, but in the end chose Baldor because of the quality of the product and because he and his team felt more comfortable with the level of support they were getting from Baldor versus the others.

“We had a preference for the bearing lubrication design of the Baldor•Reliance® large AC motors,”

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This first Baldor•Reliance motor installed was this 1,500 HP variable speed, totally enclosed, blower-cooled AC unit on the paper machine fan pump. The pump, located in the basement just below the paper machine, provides the stock flow used to put the fiber on the machine.

Domtar had the option of using a 3,000 HP motor for its boiler-feed water pump system; however, it chose to use dual-tandem Baldor•Reliance 1,500 HP variable speed, totally enclosed, blower-cooled AC motors. This engineered solution fit the existing electrical supply, so no changes had to be made to the transformers supplying power.

Features Features

The Marlboro paper mill, located in Bennettsville, South Carolina, was originally opened by Willamette in 1990 and became part of Domtar in 2007. With one pulp line and one paper machine, this mill has an annual paper production capacity of up to 389,000 tons.

Shortly after becoming a part of Domtar, mill officials determined that they needed to move the mill’s technology forward to be more in line

with the latest industry norm for paper mill applications.

That meant converting existing DC motors and drives to AC technology. The cost of rebuilding DC motors and the ongoing cost of brush maintenance also contributed to the decision to make the switch.

Bill Rogers, manufacturing services department manager at the Marlboro mill, led the effort to find not only

the right motors for the retrofit but also the right company to trust with this complex project. Rogers says they looked at a number of manufacturers, but in the end chose Baldor because of the quality of the product and because he and his team felt more comfortable with the level of support they were getting from Baldor versus the others.

“We had a preference for the bearing lubrication design of the Baldor•Reliance® large AC motors,”

Number 9 | Solutions Magazine | 1918 | Solutions Magazine | Number 9

This first Baldor•Reliance motor installed was this 1,500 HP variable speed, totally enclosed, blower-cooled AC unit on the paper machine fan pump. The pump, located in the basement just below the paper machine, provides the stock flow used to put the fiber on the machine.

Domtar had the option of using a 3,000 HP motor for its boiler-feed water pump system; however, it chose to use dual-tandem Baldor•Reliance 1,500 HP variable speed, totally enclosed, blower-cooled AC motors. This engineered solution fit the existing electrical supply, so no changes had to be made to the transformers supplying power.

Features Features

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says Rogers. “But we also liked the fact that Baldor engineers were willing to work with our plant engineers to study the options available prior to any commitments being made to purchase the motors. The Baldor team was very helpful and provided a lot of background and support engineering.”

The work that Rogers is referring to was conducted by Baldor’s paper and forest products industry team, a group dedicated to supporting this industry. The team visited the mill on several occasions, studied the application requirements and then made recommendations for an engineered solution. Michael Feldkirchner, Domtar’s senior electrical project engineer, agrees with Rogers that it was definitely good support.

Baldor•Reliance V*S Master motors, like this 200 HP totally enclosed, fan-cooled unit on the dryer, are inverter duty AC motors designed to provide full load torque continuously from 0 to base speed. The unique inverter duty insulation system in this motor eliminates the formation of corona, which can greatly shorten motor life.

Right: After reviewing and evaluating various drive options, Domtar selected ABB drives because officials have said they are the best product for the job. Raw data collected by Domtar shows the mill saved roughly 200 kVA of power with the new AC drives/motor combination versus the DC products, achieving a 10% reduction in electrical usage.

Domtar’s Marlboro Mill has an annual paper production capacity of up to 389,000 tons.

“Baldor went beyond what other manufacturers did

by supplying us with engineers to come on-site

and look at our applications.”

Michael Feldkirchner, senior electrical project

manager, Domtar's Marlboro

paper mill

“Baldor went beyond what other manufacturers did by supplying us with engineers to come on-site and look at our applications,” says Feldkirchner. “They sent us reports back for our review and made good recommendations. They made sure that what we selected worked now and would work for future upgrades, as well.”

With the decision made to purchase Baldor motors, Feldkirchner began working with engineers at the plant

where the motors were being built. Again, he says, the level of support he received from the plant was greatly appreciated.

“Baldor’s King’s Mountain plant was very helpful in getting us the drawings early in the process,” says Feldkirchner. “We really appreciated the good job the plant did in getting us the information we needed.”

The first Baldor•Reliance large AC motor installed was a 1,500 HP variable speed fan pump motor located in the basement below the paper machine. This was followed by two 1,500 HP variable speed motors installed on the boiler-feed water pump; a 1,500 HP variable speed motor installed on the biomass boiler-induced draft fan; and finally a series of eight variable speed AC motors, from 20 HP to 800 HP, installed on the dryer section of the paper machine. The majority of these motors are on critical applications, and any motor failure would stop the paper-making process, costing the mill a significant amount in lost production.

Understandably, reliability is a top concern for Rogers, but he says the mill has gotten the performance and reliability they expected from the Baldor•Reliance motors installed.“This project has been extremely successful,” says Rogers. “These motors have performed up to our expectations. We had no issues at start up, no issues with any of the motors, and everything is performing as planned.”

Changing out all of the motors from DC to AC was a major undertaking, and despite his confidence in the engineering support he received from Baldor’s industry team, Feldkirchner says he was still nervous about how everything would turn out.“Someone very wise told me that anytime you touch a motor on a paper machine it’s potentially a career-altering decision,” says Feldkirchner. “But after all of this time, we can look back and know that we definitely made the right decision.”

Features Features

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says Rogers. “But we also liked the fact that Baldor engineers were willing to work with our plant engineers to study the options available prior to any commitments being made to purchase the motors. The Baldor team was very helpful and provided a lot of background and support engineering.”

The work that Rogers is referring to was conducted by Baldor’s paper and forest products industry team, a group dedicated to supporting this industry. The team visited the mill on several occasions, studied the application requirements and then made recommendations for an engineered solution. Michael Feldkirchner, Domtar’s senior electrical project engineer, agrees with Rogers that it was definitely good support.

Baldor•Reliance V*S Master motors, like this 200 HP totally enclosed, fan-cooled unit on the dryer, are inverter duty AC motors designed to provide full load torque continuously from 0 to base speed. The unique inverter duty insulation system in this motor eliminates the formation of corona, which can greatly shorten motor life.

Right: After reviewing and evaluating various drive options, Domtar selected ABB drives because officials have said they are the best product for the job. Raw data collected by Domtar shows the mill saved roughly 200 kVA of power with the new AC drives/motor combination versus the DC products, achieving a 10% reduction in electrical usage.

Domtar’s Marlboro Mill has an annual paper production capacity of up to 389,000 tons.

“Baldor went beyond what other manufacturers did

by supplying us with engineers to come on-site

and look at our applications.”

Michael Feldkirchner, senior electrical project

manager, Domtar's Marlboro

paper mill

“Baldor went beyond what other manufacturers did by supplying us with engineers to come on-site and look at our applications,” says Feldkirchner. “They sent us reports back for our review and made good recommendations. They made sure that what we selected worked now and would work for future upgrades, as well.”

With the decision made to purchase Baldor motors, Feldkirchner began working with engineers at the plant

where the motors were being built. Again, he says, the level of support he received from the plant was greatly appreciated.

“Baldor’s King’s Mountain plant was very helpful in getting us the drawings early in the process,” says Feldkirchner. “We really appreciated the good job the plant did in getting us the information we needed.”

The first Baldor•Reliance large AC motor installed was a 1,500 HP variable speed fan pump motor located in the basement below the paper machine. This was followed by two 1,500 HP variable speed motors installed on the boiler-feed water pump; a 1,500 HP variable speed motor installed on the biomass boiler-induced draft fan; and finally a series of eight variable speed AC motors, from 20 HP to 800 HP, installed on the dryer section of the paper machine. The majority of these motors are on critical applications, and any motor failure would stop the paper-making process, costing the mill a significant amount in lost production.

Understandably, reliability is a top concern for Rogers, but he says the mill has gotten the performance and reliability they expected from the Baldor•Reliance motors installed.“This project has been extremely successful,” says Rogers. “These motors have performed up to our expectations. We had no issues at start up, no issues with any of the motors, and everything is performing as planned.”

Changing out all of the motors from DC to AC was a major undertaking, and despite his confidence in the engineering support he received from Baldor’s industry team, Feldkirchner says he was still nervous about how everything would turn out.“Someone very wise told me that anytime you touch a motor on a paper machine it’s potentially a career-altering decision,” says Feldkirchner. “But after all of this time, we can look back and know that we definitely made the right decision.”

Features Features

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Features Features

Number 9 | Solutions Magazine | 2322 | Solutions Magazine | Number 9

Features Features

Malt is a processed form of barley and is one of the basic ingredients used to brew beer. Often referred to as the “soul” of beer, malt provides most of the complex carbohydrates and sugars needed to give this beverage its distinctive flavor and color. The Malteurop Group, the world’s leading malt producer headquartered in Reims, France, has perfected the precise control required to produce premium quality malt barley.

Malteurop acquired U.S.-based ADM Malting in 2008, including a malting facility in Milwaukee, Wisconsin, a city

historically linked to the beer industry. Soon after, work began to upgrade the facility, including one of the large malt houses at the plant.

Gary McLoughlin, vice president of operations for Malteurop North America, says all 12 malting beds needed to be upgraded, replacing aging equipment with more reliable and more efficient technology. Each bed is nearly 127 feet long and 18 feet wide and holds 100 tons of cleaned and hydrated barley. Over a four-day period, 11 separate screw mixers are continuously moved back and forth through the bed,

while the barley germinates. Moisture levels are maintained or raised during this process by moving humidified air through the barley. McLoughlin says there is no room for error over this time-critical process because equipment failure can result in substandard barley malt.

“Once we give the barley water and air, there is no stopping the germination process –– the barley doesn’t care that we’ve had a breakdown, it just keeps growing,” explains McLoughlin. “If we are down too long, we’ll have to throw the batch out, and if we can’t

Number 9 | Solutions Magazine | 2524 | Solutions Magazine | Number 9

The Baldor•Reliance® SSE™ Stainless Steel Super-E® motor, with its all-stainless construction, including housing, conduit box and end plates, makes this product impervious to rust and deterioration caused by high-pressure sanitizing. Premium external and internal bearing protection prevents water from entering the motor. Encapsulation using Baldor’s E3 Effusion Epoxy Encapsulation™ process on the windings adds another level of moisture protection. The Dodge® Quantis® E-Z Kleen gear reducer is manufactured with a 13-step coating system that provides greater than three times the corrosion resistance of standard epoxy-painted units. E-Z Kleen reducers have a two-piece, harsh-duty sealing system that protects against high-pressure sprays and sanitizing solutions.

Malthouse Project Engineer Dave Hinners says they chose a Baldor•Reliance RPM AC® motor for the travel drive because it meets the unique requirements required for the application. When the travel drive is moving back and forth turning the barley, it moves just under two feet per minute. But during the unload, it moves nearly 100 feet per minute. “That’s over a 60-to-1 ratio, and we needed a motor that could handle that wide range of speed with the torque that we needed,” says Hinners. “Because the RPM AC motor offers continuous constant torque to zero speed, it’s the perfect choice for this machine.”

evacuate the bed in time, we have a real problem with backing up production because there is always a batch waiting. This is why equipment reliability is so important to us.”

Dave Hinners, the facility’s project engineer, led the in-house design effort for the upgrade. He says the high humidity required for the germination process and the extensive cleaning between batches has led to a high failure rate for both mechanical and electrical equipment. Working with Kurz Electric Solutions, a local distributor helping them with repair work, Hinners

Features Features

Malt is a processed form of barley and is one of the basic ingredients used to brew beer. Often referred to as the “soul” of beer, malt provides most of the complex carbohydrates and sugars needed to give this beverage its distinctive flavor and color. The Malteurop Group, the world’s leading malt producer headquartered in Reims, France, has perfected the precise control required to produce premium quality malt barley.

Malteurop acquired U.S.-based ADM Malting in 2008, including a malting facility in Milwaukee, Wisconsin, a city

historically linked to the beer industry. Soon after, work began to upgrade the facility, including one of the large malt houses at the plant.

Gary McLoughlin, vice president of operations for Malteurop North America, says all 12 malting beds needed to be upgraded, replacing aging equipment with more reliable and more efficient technology. Each bed is nearly 127 feet long and 18 feet wide and holds 100 tons of cleaned and hydrated barley. Over a four-day period, 11 separate screw mixers are continuously moved back and forth through the bed,

while the barley germinates. Moisture levels are maintained or raised during this process by moving humidified air through the barley. McLoughlin says there is no room for error over this time-critical process because equipment failure can result in substandard barley malt.

“Once we give the barley water and air, there is no stopping the germination process –– the barley doesn’t care that we’ve had a breakdown, it just keeps growing,” explains McLoughlin. “If we are down too long, we’ll have to throw the batch out, and if we can’t

Number 9 | Solutions Magazine | 2524 | Solutions Magazine | Number 9

The Baldor•Reliance® SSE™ Stainless Steel Super-E® motor, with its all-stainless construction, including housing, conduit box and end plates, makes this product impervious to rust and deterioration caused by high-pressure sanitizing. Premium external and internal bearing protection prevents water from entering the motor. Encapsulation using Baldor’s E3 Effusion Epoxy Encapsulation™ process on the windings adds another level of moisture protection. The Dodge® Quantis® E-Z Kleen gear reducer is manufactured with a 13-step coating system that provides greater than three times the corrosion resistance of standard epoxy-painted units. E-Z Kleen reducers have a two-piece, harsh-duty sealing system that protects against high-pressure sprays and sanitizing solutions.

Malthouse Project Engineer Dave Hinners says they chose a Baldor•Reliance RPM AC® motor for the travel drive because it meets the unique requirements required for the application. When the travel drive is moving back and forth turning the barley, it moves just under two feet per minute. But during the unload, it moves nearly 100 feet per minute. “That’s over a 60-to-1 ratio, and we needed a motor that could handle that wide range of speed with the torque that we needed,” says Hinners. “Because the RPM AC motor offers continuous constant torque to zero speed, it’s the perfect choice for this machine.”

evacuate the bed in time, we have a real problem with backing up production because there is always a batch waiting. This is why equipment reliability is so important to us.”

Dave Hinners, the facility’s project engineer, led the in-house design effort for the upgrade. He says the high humidity required for the germination process and the extensive cleaning between batches has led to a high failure rate for both mechanical and electrical equipment. Working with Kurz Electric Solutions, a local distributor helping them with repair work, Hinners

Number 9 | Solutions Magazine | 2726 | Solutions Magazine | Number 9

Features Features

The Malteurop team selected Dodge Imperial roller bearings because of the patented triple-lip contact sealing system that prevents water and other contaminants from entering the bearing. The team is also pleased with the adapter mounting system that makes these bearings easy to install and remove.

Based on the success of the other Baldor products used on the germination beds, the Malteurop team asked for a reliable gearing solution for their screw conveyor applications. Gene Gestwicki, plant maintenance and project engineer, says the existing units required constant maintenance to keep them running. When Kurz told Gestwicki about the Dodge Motorized Torque-Arm™ (MTA), a totally enclosed, shaft-mounted speed reducer, he was eager to try one. The product was a hit right out of the box. “It was an easy, straightforward installation,” says Gestwicki. “Plus, everything is sealed on the MTA, so it won’t be affected by the environment. We have more on order, and we are going to continue to replace older equipment with this new solution.”

discussed how bearings were especially troubling, difficult to maintain and even more difficult to remove. When the Kurz team demonstrated the features of the Dodge Imperial™ bearing, Hinners believed he may have found the solution.

“The unique mounting method of this bearing makes it easy to install but also easy to remove, if needed,” says Hinners. “But it’s the triple-lip sealing system that really sold us on the Imperial. The biggest enemy in our facility is water, and if we can keep water out, a major problem is solved.”

Needing to be certain before making the final decision, an Imperial bearing was installed to see how it would perform. Hinners says after an 18-month test, he got the results he was hoping for.

“Taking a bearing off in the past would have involved hydraulics, torches and saws,” says Hinners. “But the Imperial

was easy to get off. The sealing system worked because this bearing looked very good.”

“It's the triple-lip sealing system that really sold

us on the Imperial. The biggest enemy in our

facility is water, and if we can keep water out, a major problem is solved.”

Dave Hinners, facility project engineer,Malteurop Milwaukee

plant

While the bearing was under test, the Malteurop team continued to work with the Kurz team, the local Dodge field sales engineer and Baldor’s Milwaukee district office to put together the most reliable motor and gearbox package. The products had to be engineered to withstand the harsh conditions, and because this was a retro-fit, they had to fit the existing envelope. Because motors were failing due to severely corroded housings, Mike Glynn, Kurz vice president for marketing and new business development, recommended Baldor’s SSE Stainless Steel Super-E motor.

“This stainless motor is designed to perform in harsh conditions longer than anything else available today,” says Glynn. “And, to make sure we could get the right reducer to fit, Dodge sales engineer Brian Koch helped us with a design for the Dodge Quantis E-Z Kleen. And just like the bearing test, we placed a plate from the unit in the environment to prove that the reducers’

13-step coating system would hold up without rusting –– and it did.”

As an added benefit, Baldor pre-assembled the motors and gearboxes, so the Malteurop team didn’t have to worry about assembly on-site.

With the project nearly complete, McLoughlin says he’s pleased with the results. Between the performance, reliability and energy savings these products offer, he is convinced they have found the right solution. He credits the success to the skills of the in-house engineering team and the expertise provided by valued partners.

“This has been a significant project for us,” says McLoughlin. But with this collaboration and the attention to detail, the project is a success. “We knew what we wanted, and with help, we got what we wanted. And now we believe we have the right solution.”

Malted barley is the main ingredient in beer, and Malteurop is the world’s leading malt producer. The Malteurop North America plant in Milwaukee produces 220,000 tons of Pilsen-style malt used by local brewers and by companies in Kentucky and Tennessee that produce bourbon and malt whisky.

Number 9 | Solutions Magazine | 2726 | Solutions Magazine | Number 9

Features Features

The Malteurop team selected Dodge Imperial roller bearings because of the patented triple-lip contact sealing system that prevents water and other contaminants from entering the bearing. The team is also pleased with the adapter mounting system that makes these bearings easy to install and remove.

Based on the success of the other Baldor products used on the germination beds, the Malteurop team asked for a reliable gearing solution for their screw conveyor applications. Gene Gestwicki, plant maintenance and project engineer, says the existing units required constant maintenance to keep them running. When Kurz told Gestwicki about the Dodge Motorized Torque-Arm™ (MTA), a totally enclosed, shaft-mounted speed reducer, he was eager to try one. The product was a hit right out of the box. “It was an easy, straightforward installation,” says Gestwicki. “Plus, everything is sealed on the MTA, so it won’t be affected by the environment. We have more on order, and we are going to continue to replace older equipment with this new solution.”

discussed how bearings were especially troubling, difficult to maintain and even more difficult to remove. When the Kurz team demonstrated the features of the Dodge Imperial™ bearing, Hinners believed he may have found the solution.

“The unique mounting method of this bearing makes it easy to install but also easy to remove, if needed,” says Hinners. “But it’s the triple-lip sealing system that really sold us on the Imperial. The biggest enemy in our facility is water, and if we can keep water out, a major problem is solved.”

Needing to be certain before making the final decision, an Imperial bearing was installed to see how it would perform. Hinners says after an 18-month test, he got the results he was hoping for.

“Taking a bearing off in the past would have involved hydraulics, torches and saws,” says Hinners. “But the Imperial

was easy to get off. The sealing system worked because this bearing looked very good.”

“It's the triple-lip sealing system that really sold

us on the Imperial. The biggest enemy in our

facility is water, and if we can keep water out, a major problem is solved.”

Dave Hinners, facility project engineer,Malteurop Milwaukee

plant

While the bearing was under test, the Malteurop team continued to work with the Kurz team, the local Dodge field sales engineer and Baldor’s Milwaukee district office to put together the most reliable motor and gearbox package. The products had to be engineered to withstand the harsh conditions, and because this was a retro-fit, they had to fit the existing envelope. Because motors were failing due to severely corroded housings, Mike Glynn, Kurz vice president for marketing and new business development, recommended Baldor’s SSE Stainless Steel Super-E motor.

“This stainless motor is designed to perform in harsh conditions longer than anything else available today,” says Glynn. “And, to make sure we could get the right reducer to fit, Dodge sales engineer Brian Koch helped us with a design for the Dodge Quantis E-Z Kleen. And just like the bearing test, we placed a plate from the unit in the environment to prove that the reducers’

13-step coating system would hold up without rusting –– and it did.”

As an added benefit, Baldor pre-assembled the motors and gearboxes, so the Malteurop team didn’t have to worry about assembly on-site.

With the project nearly complete, McLoughlin says he’s pleased with the results. Between the performance, reliability and energy savings these products offer, he is convinced they have found the right solution. He credits the success to the skills of the in-house engineering team and the expertise provided by valued partners.

“This has been a significant project for us,” says McLoughlin. But with this collaboration and the attention to detail, the project is a success. “We knew what we wanted, and with help, we got what we wanted. And now we believe we have the right solution.”

Malted barley is the main ingredient in beer, and Malteurop is the world’s leading malt producer. The Malteurop North America plant in Milwaukee produces 220,000 tons of Pilsen-style malt used by local brewers and by companies in Kentucky and Tennessee that produce bourbon and malt whisky.

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Gets Barge Conveyor

Back Up and Running

BALDOR’S DODGE® MAGNAGEAR™ IN-STOCK PROGRAM

Number 9 | Solutions Magazine | 2928 | Solutions Magazine | Number 9

Gets Barge Conveyor

Back Up and Running

BALDOR’S DODGE® MAGNAGEAR™ IN-STOCK PROGRAM

Features Features

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In August 2011, Baldor launched the Dodge MagnaGear in-stock program, designed to help customers quickly replace failed competitor units. By Baldor stocking the most common sizes and ratios of this power-dense, heavy-duty large gearbox, customers would no longer have to wait weeks and weeks to get a replacement unit.

The timing of the program could not have been better for the owners of the Louisiana Mid-Stream One (LMO), a unique barge-mounted conveying system located on the Mississippi River near New Orleans. Working in tandem with a separate barge-mounted crane, coal from a barge is directly fed into

the receiving hoppers of the LMO. After the coal is combined, it travels up a series of conveyors to a retractable loading boom that feeds an ocean-going export vessel.

The LMO, a brand new rig, was scheduled to start loading vessels in early September 2011. But, during the final test prior to the first load out, a catastrophic failure of one of the three gearboxes on the conveyor system shut the rig down. Company representative Andy Matherne said they already had vessels booked in anticipation of the LMO start-up, and every day they couldn’t load coal was going to cost his company a great deal of money.

“We are allowed a certain amount of time to load a vessel, but once we go beyond that, we have to pay a penalty,” explains Matherne. “Typically it’s about twenty thousand dollars per day, but in this particular circumstance, with so many vessels on anchor waiting to come in, we were sitting on fifty thousand dollars a day. Obviously the longer it took for us to get running, the more money it was going to cost us.”

The situation was frustrating to the LMO team because, according to Matherne, they couldn’t get the kind of help they needed from the gearbox manufacturer. With a fifty thousand dollar a day penalty hanging over their

head, they could not afford to wait eight to 10 weeks for a replacement. Matherne says that’s when they decided to call Jim McLain, co-owner of Allied Bearing & Supply.

“I have had a long relationship with Jim, and he has provided equipment and expertise for us on many other projects,” says Matherne. “When it comes to conveying equipment and gearboxes, Jim knows more about this kind of equipment than anyone else I know. We were confident that if anyone could help us out, it was Jim.”

McLain says he received an email with a photo of the failed gearbox asking if he could help late on Sunday, August 28, 2011. After getting more details on Monday, he believed he could find a gearbox by taking advantage of the new MagnaGear quick-ship program. Not only did he find the right size MagnaGear to replace the failed gearbox, but he also found two more units in case his customer wanted to change out the other units on the rig. On Tuesday, he presented the solution to the LMO team.

“By Wednesday, we got the order for all three MagnaGear reducers, because the customer didn’t want to take any more chances with gearboxes,” says McLain. “I know that the team jumped through

hoops at the Dodge gear plant to get couplings rebored and get additional shaft fans, but everything showed up at the LMO site on Saturday. With a lot of work behind the scenes, we were able to help a customer get out of a very bad situation.”

Not only did the customer get the reducers in just a couple of days,

but McLain says they actually got a superior product that’s much better suited for this conveyor application. He says Dodge gearing is known for reliability, and because of its power- dense design, the MagnaGear offers more power in a smaller package.

“The MagnaGear reducers provide the output torque twice of the boxes

The Louisiana Mid-Stream One (LMO) is a unique barge-mounted conveying system with quality control features not found in other midstream loading operations, including a magnet, mechanical sampling system, belt scale and water drainage. The LMO can simultaneously feed and combine product from multiple barges to meet quality specifications, enhancing the quality of export coal.

Not only did the customer get the MagnaGear reducers in three days, but Jim McLain, with Allied Bearing & Supply, says the customer got a product much better suited for this application. He says the MagnaGear reducers provide twice the output torque than the boxes they replaced, plus the right-angle configuration of the reducer is a perfect fit for this conveyor design.

“This experience has shown me the capability

of the company and the ‘can do’ attitude of the people behind the

products.”

Jim McLain, co-owner,

Allied Bearing & Supply

Features Features

Number 9 | Solutions Magazine | 3130 | Solutions Magazine | Number 9

In August 2011, Baldor launched the Dodge MagnaGear in-stock program, designed to help customers quickly replace failed competitor units. By Baldor stocking the most common sizes and ratios of this power-dense, heavy-duty large gearbox, customers would no longer have to wait weeks and weeks to get a replacement unit.

The timing of the program could not have been better for the owners of the Louisiana Mid-Stream One (LMO), a unique barge-mounted conveying system located on the Mississippi River near New Orleans. Working in tandem with a separate barge-mounted crane, coal from a barge is directly fed into

the receiving hoppers of the LMO. After the coal is combined, it travels up a series of conveyors to a retractable loading boom that feeds an ocean-going export vessel.

The LMO, a brand new rig, was scheduled to start loading vessels in early September 2011. But, during the final test prior to the first load out, a catastrophic failure of one of the three gearboxes on the conveyor system shut the rig down. Company representative Andy Matherne said they already had vessels booked in anticipation of the LMO start-up, and every day they couldn’t load coal was going to cost his company a great deal of money.

“We are allowed a certain amount of time to load a vessel, but once we go beyond that, we have to pay a penalty,” explains Matherne. “Typically it’s about twenty thousand dollars per day, but in this particular circumstance, with so many vessels on anchor waiting to come in, we were sitting on fifty thousand dollars a day. Obviously the longer it took for us to get running, the more money it was going to cost us.”

The situation was frustrating to the LMO team because, according to Matherne, they couldn’t get the kind of help they needed from the gearbox manufacturer. With a fifty thousand dollar a day penalty hanging over their

head, they could not afford to wait eight to 10 weeks for a replacement. Matherne says that’s when they decided to call Jim McLain, co-owner of Allied Bearing & Supply.

“I have had a long relationship with Jim, and he has provided equipment and expertise for us on many other projects,” says Matherne. “When it comes to conveying equipment and gearboxes, Jim knows more about this kind of equipment than anyone else I know. We were confident that if anyone could help us out, it was Jim.”

McLain says he received an email with a photo of the failed gearbox asking if he could help late on Sunday, August 28, 2011. After getting more details on Monday, he believed he could find a gearbox by taking advantage of the new MagnaGear quick-ship program. Not only did he find the right size MagnaGear to replace the failed gearbox, but he also found two more units in case his customer wanted to change out the other units on the rig. On Tuesday, he presented the solution to the LMO team.

“By Wednesday, we got the order for all three MagnaGear reducers, because the customer didn’t want to take any more chances with gearboxes,” says McLain. “I know that the team jumped through

hoops at the Dodge gear plant to get couplings rebored and get additional shaft fans, but everything showed up at the LMO site on Saturday. With a lot of work behind the scenes, we were able to help a customer get out of a very bad situation.”

Not only did the customer get the reducers in just a couple of days,

but McLain says they actually got a superior product that’s much better suited for this conveyor application. He says Dodge gearing is known for reliability, and because of its power- dense design, the MagnaGear offers more power in a smaller package.

“The MagnaGear reducers provide the output torque twice of the boxes

The Louisiana Mid-Stream One (LMO) is a unique barge-mounted conveying system with quality control features not found in other midstream loading operations, including a magnet, mechanical sampling system, belt scale and water drainage. The LMO can simultaneously feed and combine product from multiple barges to meet quality specifications, enhancing the quality of export coal.

Not only did the customer get the MagnaGear reducers in three days, but Jim McLain, with Allied Bearing & Supply, says the customer got a product much better suited for this application. He says the MagnaGear reducers provide twice the output torque than the boxes they replaced, plus the right-angle configuration of the reducer is a perfect fit for this conveyor design.

“This experience has shown me the capability

of the company and the ‘can do’ attitude of the people behind the

products.”

Jim McLain, co-owner,

Allied Bearing & Supply

32 | Solutions Magazine | Number 9

they replaced,” says McLain. “Plus, because it’s available in a right-angle configuration, it was a perfect fit for this conveyor design. These reducers are built for tough environments, and they are going to last for a very long time.”

Matherne gives McLain the credit for quickly finding the solution that ended up saving the company a great deal of money. For his part, McLain says it’s this kind of experience that really makes him proud to be a Dodge distributor.

“You look across the Dodge product line, and you see the quality and a company that tries to do more with products, not less,” says McLain. “This experience has also shown me the capability of the company and the ‘can do’ attitude of the people behind the products. There were a lot of hoops to jump through and a lot of extra work to get these gearboxes delivered to the customer this quickly, and it speaks very highly of all of the people who were involved.”

Because the Dodge MagnaGear in-stock program includes the most common sizes and ratios of this heavy-duty gearbox, customers now have an option of quickly replacing failed competitor units. Instead of waiting up to 10 weeks for a replacement from the original manufacturer, the LMO team was able to get three right-angle Dodge units, like this one, in only three days after the order was placed.

Features

Based on the success of the

MagnaGears running on the

LMO, when a gearbox failed on

one of the four feeders on the rig,

McLain recommended the Dodge

Motorized Torque-Arm™ (MTA)

as a replacement. “The customer

wanted to get away from the parallel

shaft overhung design of the failed

gearbox,” says McLain. “The MTA is

the ideal choice because it eliminates

the overhung load and all of the

issues they had with couplings and

alignment. The MTA will be easier

for them to maintain, plus it gives

the employees more room to work.

• Superior Reliability

• Unmatched Quality

• Local Sales and Support

• Quickest Delivery Available

When it comes to industrial electric motors, power transmission products and drives, no other manufacturer offers more than Baldor...that is why Baldor is The Industrial Choice! Whether your application requires a fractional or 15,000 Hp motor, a variable frequency drive, mounted bearings or gearing, a pulley or sheave or even a standby generator, Baldor is the choice most preferred by industry.

When your next project demands the most reliable and energy efficient products available, look to Baldor as your one source for more industrial solutions.

baldor.com 479-646-4711

The Industrial Choice

32 | Solutions Magazine | Number 9

they replaced,” says McLain. “Plus, because it’s available in a right-angle configuration, it was a perfect fit for this conveyor design. These reducers are built for tough environments, and they are going to last for a very long time.”

Matherne gives McLain the credit for quickly finding the solution that ended up saving the company a great deal of money. For his part, McLain says it’s this kind of experience that really makes him proud to be a Dodge distributor.

“You look across the Dodge product line, and you see the quality and a company that tries to do more with products, not less,” says McLain. “This experience has also shown me the capability of the company and the ‘can do’ attitude of the people behind the products. There were a lot of hoops to jump through and a lot of extra work to get these gearboxes delivered to the customer this quickly, and it speaks very highly of all of the people who were involved.”

Because the Dodge MagnaGear in-stock program includes the most common sizes and ratios of this heavy-duty gearbox, customers now have an option of quickly replacing failed competitor units. Instead of waiting up to 10 weeks for a replacement from the original manufacturer, the LMO team was able to get three right-angle Dodge units, like this one, in only three days after the order was placed.

Features

Based on the success of the

MagnaGears running on the

LMO, when a gearbox failed on

one of the four feeders on the rig,

McLain recommended the Dodge

Motorized Torque-Arm™ (MTA)

as a replacement. “The customer

wanted to get away from the parallel

shaft overhung design of the failed

gearbox,” says McLain. “The MTA is

the ideal choice because it eliminates

the overhung load and all of the

issues they had with couplings and

alignment. The MTA will be easier

for them to maintain, plus it gives

the employees more room to work.

• Superior Reliability

• Unmatched Quality

• Local Sales and Support

• Quickest Delivery Available

When it comes to industrial electric motors, power transmission products and drives, no other manufacturer offers more than Baldor...that is why Baldor is The Industrial Choice! Whether your application requires a fractional or 15,000 Hp motor, a variable frequency drive, mounted bearings or gearing, a pulley or sheave or even a standby generator, Baldor is the choice most preferred by industry.

When your next project demands the most reliable and energy efficient products available, look to Baldor as your one source for more industrial solutions.

baldor.com 479-646-4711

The Industrial Choice

P.O. Box 2400, Fort Smith, AR 72902-2400 USA, Ph: (1) 479.646.4711, Fax: (1) 479.648.5792, International Fax: (1) 479.648.5895

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