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 specifications, a zinc refinery needed a modern retrofit that wouldn’t require re-engineering its aging conveyor system.

SEW-EURODRIVE and BDI developed a standardized solution using KA157 helical-bevel gear units and 20 HP brakemotors, with symmetrical gear housings for left- and right-hand installations and no modifications to the existing conveyor structure.

Challenge:

Obsolete Drives, Uncertain Specs, and Multiple Variants 

The facility was running exit conveyors powered by original 1970s-era gear drives, including a mix of worm and helical reducers with undocumented gear ratios, unreadable nameplates, and no replacement parts available. The three conveyor lines also required both left- and right-hand drive configurations and used different motor sizes of 20 and 30 HP, further complicating replacement and spare parts requirements.

With the original equipment no longer serviceable, the facility needed a retrofit that could replace the existing drives without re-engineering the conveyor 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, developed a retrofit solution using KA157 helical-bevel gear units and 20 HP brakemotors. With gear ratios undocumented and the original nameplates unreadable, SEW used the original conveyor drawings along with on-site speed and torque measurements to determine the required system performance and properly size the replacement gear units.

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

 

Application Summary:

Application Areas:

  • Exit Conveyors

SEW-EURODRIVE Product(s):

  • K Series helical-bevel gear units and brake motors
    KA157 / T DRN160L4 / BE20HR helical-bevel gear units
    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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