CASE STUDY:  

Conveyor Retrofit Without Re-engineering

Retrofit Mastery: SEW-EURODRIVE Standardizes Exit Conveyors Without Re-engineering

Faced with failing 1970s-era drives and no usable specs, a zinc refinery needed a modern retrofit that wouldn’t require re-engineering their aging conveyor system.

SEW-EURODRIVE and BDI delivered standardized KA157 gear units and 20 HP brakemotor solution with symmetrical mounting and motor consolidation—future-proofing the application with modular precision and zero structural modification.

Challenge:

Obsolete Drives, Uncertain Specs, and Multiple Variants 

The facility was running exit conveyors powered by original 1970s-era gear drives, an aging mix of worm and helical reducers with undocumented gear ratios, unreadable nameplates, and zero parts availability. The three conveyor lines required both left- and right-hand configurations and different motor sizes (20 and 30 HP), adding to the complexity. Downtime risks loomed large, with no path forward using OEM parts. The facility needed a future-ready retrofit, but without re-engineering the system.

“We didn’t just replace gearboxes—we future-proofed the system.” 
—  Patrick Miller, District Sales Engineer, SEW-EURODRIVE 

 

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BEFORE: 1970's-era Gear Drive
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AFTER: Drop-in solution - KA157 helical-bevel gear unit

Solution:

Standardized KA157 Gear Unit Retrofit with Smart Mounting 

SEW-EURODRIVE, in partnership with BDI, engineered a flexible drop-in solution using KA157 helical-bevel gear units and 20 HP brake motors. SEW reverse-engineered system performance using original conveyor drawings and on-site speed and torque measurements to size the gear units precisely.

Key design elements:

  • A torque arm and integral motor design allowed the new gear units to be installed without structure modification.
  • Symmetrical gear housings supported both left- and right-hand installations—reducing part variation.
  • Motor standardization replaced legacy 20/30 HP setups with a single optimized 20 HP unit.
  • Improved energy efficiency eliminated worm gearing losses, reducing operating cost.

“The fact that one unit works on all three conveyors is a huge win for us. It reduces spares and makes maintenance easier.”
—  Facility Maintenance Lead

 

SEW-EURODRIVE Advantage:

Modular thinking. Custom execution. 

Delivering a retrofit built for the next 30 years. Despite incomplete information on the reducers from the client’s older system, our team was able to use reverse-engineering to consolidate drive types and deliver a modernized retrofit using standard components—without altering conveyor structure. That agility, combined with modular gearmotors and local engineering support, made SEW the ideal partner.

Application Summary:

Application Areas:

  • Off-load bucket elevator

SEW-EURODRIVE Product(s):

  • K Series helical-bevel gear units and brake motors
    KA157 / T DRN160L4 / BE20HR 
    20 HP brake motors
    Ratio: 122.39:1
    Torque: 87,400lb-in

INDUSTRY:

 Metallurgy / Industrial Processing 

APPLICATION:

Exit Conveyor Drive System

PREVIOUS TECHNOLOGY:

 1970's-era Gear Drives 

SOLUTION:

K Series Gear Unit
20 HP Brakemotor
   KA157 / T DRN160L4 / BE20HR

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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 

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