CASE STUDY:  

Retrofit with Direct Drive

From Critical Failures to Critical Partner: Direct Drive Solution Eliminates Downtime and Simplifies Production

By replacing a costly, failure-prone legacy drivetrain with a single integrated gearmotor and VFD, SEW-EURODRIVE helped a fused mineral manufacturer eliminate unplanned downtime in a critical mixer—saving tens of thousands in maintenance and repairs. The system continues to run flawlessly, proving the value of engineering simplicity and reliability from a single source.

Challenge:

Complex Legacy System, Costly Gear Failures

The manufacturer relied on a multi-vendor mechanical drive system to power a critical V-style mixer. The legacy configuration included a motor, brake, reducer, and a massive bull gear driven by a pinion shaft. Failures in the bull gear—costing ~$20K per event—not only stalled production for days or weeks but also increased labor, sourcing, and repair burdens.

Despite attempts to solve the issue with material changes (e.g., switching to nylon pinions), the system remained unreliable and expensive to maintain.

“SEW-EURODRIVE helped us eliminate a recurring failure point and simplified our system. We haven’t had a single issue since—and we’re  rolling it out to more lines.”
— Maintenance, Fused Mineral Manufacturer

 

SEW_BEFORE_9MD1514_wash mills 4
BEFORE: Multi-vendor mechanical drive system
SEW_AFTER_9MD1514_wash mills 3
AFTER: Direct drive retrofit with a VFD

Solution:

SEW-EURODRIVE Simplifies with Direct Drive

Working through their local distributor, the facility partnered with SEW‑EURODRIVE to provide a direct drive retrofit, including a VFD.

Project details include:

  • Replaced the entire multi-part drivetrain with a single SEW-EURODRIVE gearmotor
  • Integrated a VFD with a crawl function for speed control and positioning

  • Eliminated all third-party dependencies

  • Discussed control scheme with their maintenance engineer to select a cost-effective VFD for the application.

  • Provided hands-on support during motor commissioning until the customer fully understood the process.

The result? A unified, streamlined system with zero unplanned downtime.

SEW-EURODRIVE Advantage:

Engineered as a Whole. Delivered as One. Delivering Total Solutions. 

SEW-EURODRIVE delivered a total solution: Motor, Integral Gear Unit, Brake, VFD, Application Modeling, and Field Commissioning, all from one source. With deep experience retrofitting aging infrastructure and a commitment to collaborative engineering, SEW-EURODRIVE turned a repeat failure point into a model of reliability.

“This is what SEW-EURODRIVE does best—integrate, simplify, and perform. We delivered long-term reliability with a single engineered solution.”
—  Dennis Phillips, District Sales Engineer, SEW-EURODRIVE USA

 

Application Summary:

Application Area

V-Style Mixer

SEW-EURODRIVE Products

Gearmotor Unit
R167 DRN160L4/BE20HR
Ratio 93.19:1
177,000 lb-in TQmax
4.75 (in) solid shaft
BE20 brake with optional hand release
1,770 lb-in brake TQ
20HP motor Constant TQ 300-1800rpm

VFD
MOVITRAC MCLTPB0185-5A3-4-40

Brake Resistor
BW147-T

INDUSTRY:

Fused Minerals / Abrasives

APPLICATION:

V-Style Mixer

PREVIOUS TECHNOLOGY:

Multi-vendor Mechanical Drive System 

SOLUTION:

 R Series Gearmotor  
   R167 DRN160L4/BE20HR

MOVITRAC VFD

JOIN OUR NEWSLETTER:

Image Gallery:

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 

4964_14_SEW-Service_600x600

Quick Links: