Keeping Critical Conveyors Running
Global Parcel Carrier Improves Conveyor Reliability with Predictive Maintenance
A global package delivery and logistics company operates approximately 800 SEW-EURODRIVE K Series helical-bevel gearmotors throughout one of its parcel distribution facilities. These drives power the conveyor systems that keep packages moving through the operation every day.
Because unexpected gearmotor failures can interrupt package flow and require emergency repairs, the customer wanted a way to identify developing mechanical issues before they resulted in unplanned downtime. The company partnered with SEW-EURODRIVE to implement a predictive maintenance program focused on its most critical conveyor assets.
Challenge:
Finding Problems Before They Cause Downtime
Some of the facility’s most demanding conveyor applications, particularly power turn conveyors, operate under heavy loads and continuous use. These demanding conditions place significant stress on drivetrain components, making early detection of developing mechanical issues especially important.
Without condition monitoring, maintenance teams often don’t know a gearmotor is developing a problem until it fails. The result is emergency repairs, unexpected downtime, and interruptions to package movement.
The facility needed a solution that could monitor the health of its most critical gearmotors and provide early warning before potential failures occurred.
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Solution:
Monitoring the Equipment That Matters Most
SEW-EURODRIVE implemented DriveRadar® APPredict by installing wireless vibration and temperature sensors on 125 K Series gearmotors throughout the facility.
The project was completed in two phases:
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August 2025: Installed 50 wireless sensors and one cloud-connected gateway.
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September 2025: Installed 75 additional sensors and a second gateway.
Rather than monitoring every gearmotor, the customer selected the equipment most critical to its operation, including power turns, primary sorters, and other key conveyor applications.
The sensors continuously monitor vibration and temperature while the equipment is operating. If conditions begin to change, maintenance personnel receive an early warning that a gearmotor may be developing a mechanical issue. This allows repairs to be scheduled during planned maintenance windows instead of responding to unexpected equipment failures.
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“With DriveRadar monitoring our priority motors around the clock, we have greater confidence in the health of our equipment. The early warning notifications have allowed us to proactively address issues before they resulted in failures, helping us avoid unexpected conveyor downtime and maintain operational reliability.” - Plant Manager |
Results:
Replacing Emergency Repairs with Planned Maintenance
DriveRadar® APPredict gave the user greater visibility into the health of its critical conveyor drives. By identifying developing issues before failure, maintenance teams were able to schedule corrective work during planned shutdowns rather than responding to unexpected failures during operating hours.
The project delivered measurable results:
- Installed 125 wireless condition monitoring sensors on critical K Series gearmotors
- Identify potential issues before drive failure, preventing breakdowns that disrupt processing up to 35,000 packages per hour
- Corrective maintenance could be completed during planned shutdowns.
- Expanded the successful deployment to an additional facility in California on 30 gearmotors.
- Positioned DriveRadar® APPredict for future deployment at additional facilities across the U.S.
Application Summary:
K Series on Conveyor Turns
KT39/T DRN100L4
- Motor power: 5 HP
- Output speed [r/min]: 626
- Ratio: 2.81
- Output torque: 495 lb-in
- Mounting position: M4AB
- Motor power: 30 HP
- Output speed [r/min]: 129
- Ratio: 13.85
- Output torque: 14,400 lb-in
- Mounting position: M4A
CUSTOMER:
Global Package Delivery and Logistics Company, North Baltimore, Ohio
INDUSTRY:
APPLICATION:
Parcel Sorting Conveyors
SOLUTION:
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About SEW-EURODRIVE
Founded in 1931 in Bruchsal, Germany, SEW-EURODRIVE is a global leader in Industrial Automation, with operations in over 50 countries, 17 manufacturing plants, 92 assembly facilities, and more than 21,000 employees. The company holds over 1,000 patents, continuously driving technological advancements in gearmotors, frequency inverters, servo drives, and Industry 4.0 solutions.
SEW-EURODRIVE provides engineered solutions in countless industries, including automotive, food & beverage, pharmaceuticals, mining, steel, logistics, energy, and more, providing customized automation solutions that enhance efficiency, productivity, and sustainability. Despite its global reach, SEW-EURODRIVE remains family-owned, ensuring long-term vision, strong values, and a commitment to excellence.
SEW-EURODRIVE. Driving the World™
SEW-EURODRIVE, Inc.
220 Finch Road
Wellford, SC 29385
(P): (864) 439-7537
cslyman@seweurodrive.com
www.seweurodrive.com
