CASE STUDY:  

Reducing Waste in Wastewater Treatment

25%* Decrease in annual maintenance costs.

A municipal wastewater facility faced persistent maintenance issues with its screw-lift drive system, resulting in frequent breakdowns and continuous repair expenses.

Challenge

The existing system — relying on pulleys and sheaves — was prone to wear and tear, necessitating frequent repairs and replacements, incurring significant costs and causing constant operational disruptions.
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BEFORE: Pulleys and Sheaves System
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AFTER: Modern Direct Drive (MC Series)
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For the main elevator drive;  125 HP motor with 323,800 lb-in of torque

Screw Lifts
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MC Series Heavy Industrial Gear Unit

Solution

SEW-EURODRIVE's engineering team worked closely with the wastewater facility to design and implement the direct drive solution, which would eliminate belts and pulleys and create significant system efficiencies. This Retrofit Service addressed the first and critical process in the wastewater treatment flow, where influent water is lifted from its low-level entry to begin the treatment journey.

Using MC Series units with a special mounting adapter plate, SEW-EURODRIVE’s solution offered several advantages:

  • Increased Reliability
    With fewer moving parts and a simplified design, the direct drive solution offered improved reliability and reduced susceptibility to breakdowns.
  • Enhanced Efficiency
    The direct drive solution provided efficient power transmission, optimizing energy consumption and reducing operational costs.
  • Customization
    SEW-EURODRIVE customized the direct drive solution to seamlessly integrate with the existing infrastructure, minimizing installation time and disruptions.

Results

SEW-EURODRIVE’s direct drive solution yielded significant benefits:

  • Cost Savings: By eliminating the need for frequent replacements of pulleys and sheaves, the plant saved thousands of dollars annually in repair costs.
  • Operational Efficiency: The enhanced reliability andreduced downtime resulted in uninterrupted sewage treatment operations, ensuring consistent service to the community.
  • Long-Term Reliability: The direct drive solution provided long-term reliability, offering peace of mind to plantoperators and management.
  • Improved Sustainability: With reduced energy consumptionand minimized maintenance requirements, the direct drive solution contributed to the plant’s sustainability goals.

Project Specs

  • Two MC Series gear units
  • Powered by 125 HP motor
  • Output torque of 209,700 lb-in.
  • 36 RPM output speed
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INDUSTRY:

Wastewater Treatment

APPLICATION:

Screw-Lift

PREVIOUS TECHNOLOGY:

Pulleys and sheaves 

SOLUTION:

SEW-EURODRIVE MC Series
direct drive solution

*25% is an estimated figure based on significantly improved efficiencies gained with new gearbox design

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 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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