Beltless Screw Conveyor Drives Offer Lowest Total Cost
Facilities may experience savings up to 40 percent
The advent of beltless screw conveyor drives has saved many companies time and money while increasing productivity. Total lifetime operating cost savings - as much as 40 percent - are possible when lower initial and maintenance costs, and increased productivity are considered. Additionally, workplace safety is also enhanced in beltless drive applications.
A beltless screw conveyor drive system has fewer components because the motor is directly coupled to the gear drive thus eliminating several components required in a traditional belted configuration. Fewer operating elements result in more efficient operation and reduced maintenance.
Screw conveyors are used to convey, elevate and mix a wide range of materials in cement, chemical, food, grain, mining and other material handling applications.
Traditionally, screw conveyor drive configurations have featured a myriad of components including motor, motor mounts, shims, belts, guards, gear drive, couplings and more. However, in recent years, beltless screw conveyors drives - a unified, single-package system that direct couples the motor and drive - have come on the scene.
Reduced Initial Costs
Not only are lower lifetime operating costs possible with the substitution of beltless screw conveyor drives for a belted system, but initial costs may lower as well. The efficiencies of a single-package configuration may result in lower purchase and installation costs compared to a multi-component belted drive system.
Reduced Installation Costs
In a typical application, it may take up to five hours to fully install a traditional belted screw conveyor drive system. A beltless drive configuration can be outfitted and installed in a fraction of the time. Beltless screw conveyor drives provide a simple, clean direct connection aiding in the reduction of installation costs and enhancing productivity. The decreased time and cost associated with installation reduces downtime. The significant difference in assembly time is due to the additional parts involved in a belted screw conveyor drive.
Customer-preferred motors can be mounted to the drive in less than five minutes in applications where the motor and drive are separately purchased. When considering this option, check that the gear drive can be connected to the motor without special and costly motor adaptor systems.
Reduced Maintenance Costs
The cost savings do not stop after installation. There are several ways a beltless screw conveyor drive continues to help facilities experience reduced costs compared to a belted system. Maintenance is dependent on several factors, including the location of the conveyor (inside vs. outside), the cleanliness of the environment and the hours of operation. For example, a conveyor inside a food processing plant transporting corn flakes requires less maintenance compared to a conveyor at a mining site moving coal. In addition, it is always recommended, regardless of the environment, to check the oil on a regular basis.
Monitoring belt condition is a never-ending maintenance operation. In a traditional configuration, if belts get wet they may slip or if they get too hot they may deteriorate - both instances may damage the unit forcing the facility to halt production. In addition, belt tension requires constant maintenance. Such operational requirements and on-going maintenance are not required in a beltless application.
Of course, beltless drive systems require maintenance, but not nearly as much as a belted drive. Labor time and costs are greatly reduced with the application of beltless conveyor drives. Periodic maintenance will include checking oil levels, lubrication, and occasional oil, sound and vibration analysis. The drive manufacturer will recommend a maintenance schedule.
Improved Sealing
Oil leaks are often problematic in gear drive applications. In the initial purchase process, consider the conveyor drives sealing system. A high-performance sealing system can virtually eliminate operational oil leak problems while keeping contaminants out. This is important in any application, but especially where high-sanitary conditions are required. Ask the drive manufacturer to explain details of the sealing system. Sealing systems using DuPont's Vitonā high-performance elastomer are especially effective in protecting seals from high heat up to
400° F/200° C. This temperature is nearly double the sealing capacity of a typical mitral seal.
Enhanced Safety
With the elimination of belts and associated rotating elements, job site safety is greatly enhanced when beltless conveyor drives are employed. In addition, one of the biggest industries for screw conveyors is grain. Due to the build up of gases in a silo, explosions or fires damaging the equipment or causing physical harm may occur. The beltless configuration reduces the chance of such disastrous occasions because of the direct connection with the C-Face motor.
Greater Energy Efficiency
Beltless screw conveyor drives are inherently more energy efficient with the removal of the belt in the power transfer process and the direct transmission from the motor to the gear drive. During the initial purchase process, look for a gear motor supplier providing a high-efficient motor/gear drive combination. Compared to a belted drive package, a high-efficient beltless conveyor drive can cut energy costs in half over the course of a year's operation.
Additional Selection Criteria
There are other factors to consider when selecting and comparing beltless screw conveyor drives.
For example:
- Select a drive that offers bushings that eliminate fretting, delivers positive torque and offers easy installation and removal
- Adjusting for overloads: Consider a unit that incorporates an electronic overload sensor shut-off switch.
- Select modular design units helping to ensure local availability, easily fitted spare parts and accessories, and ability to drop unit components into other manufacturers products to facilitate replacements and retrofits.
For all the benefits of lower lifetime ownership costs including low initial costs, maintenance and enhanced productivity, beltless motor/drive configurations are continuing to grow in screw conveyor applications.
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