Built to Last - Albert Frei Sons Choose Baldor

Built to Last - Albert Frei Sons Choose Baldor
F e at u r e s
Built
to Last...
F e at u r e s
Albert Frei & Sons
Choose Baldor Products
for
Crushing Plant Expansion
When they were young, the Frei children often went to work with their dad and
got to play in what Albert Frei, Jr., describes as a very large sandbox. Growing up,
he always knew he would work in the family business, and even as a young man,
started dreaming of ways to expand and grow their quarry operation.
Grateful for what their grandfather and father had done to build this family
business, the Frei children and senior management, led by Al, Jr., wanted to build
something that they could pass on to the next generation. By carefully choosing
products and creating new partnerships, the dream became a reality in August
2010, when the quarry started producing rock in its brand new, state-of-the-art,
multimillion-dollar crushing plant.
14 | Solutions Magazine | Number 4
Number 4 | Solutions Magazine | 15
F e at u r e s
Built
to Last...
F e at u r e s
Albert Frei & Sons
Choose Baldor Products
for
Crushing Plant Expansion
When they were young, the Frei children often went to work with their dad and
got to play in what Albert Frei, Jr., describes as a very large sandbox. Growing up,
he always knew he would work in the family business, and even as a young man,
started dreaming of ways to expand and grow their quarry operation.
Grateful for what their grandfather and father had done to build this family
business, the Frei children and senior management, led by Al, Jr., wanted to build
something that they could pass on to the next generation. By carefully choosing
products and creating new partnerships, the dream became a reality in August
2010, when the quarry started producing rock in its brand new, state-of-the-art,
multimillion-dollar crushing plant.
14 | Solutions Magazine | Number 4
Number 4 | Solutions Magazine | 15
F e at u r e s
F e at u r e s
“In my world,
Baldor•Dodge products
are the best of the best.
All the products are built
tough, from gearing to
bearings, to the heavyduty pulleys.”
Albert Frei, Jr., president,
Albert Frei & Sons
products with proven performance
and dependability. And since he had a
wealth of experience with Baldor•Dodge
Torque-Arm gearing, the choice for all
the mechanical products was clear.
™
“In my world, Baldor•Dodge products
are the best of the best,” exclaims Frei.
“All the products are built tough, and
you can get everything you need, from
gearing to bearings, to the heavy-duty
pulleys. These were exactly the products
I wanted, but my fear was I wouldn’t be
able to afford what I see as the top of
the line.”
With Albert Frei’s desire to build a plant that will last for the next 60 to 70 years, he wasn’t looking to buy the cheapest products. Instead, he wanted products
with proven performance and dependability. For Frei, that meant choosing Baldor•Dodge® mechanical products and Baldor•Reliance® motors.
In 1982, the family opened their
Walstrum facility, a large-capacity
granite quarry. With more than 1,800
acres, the quarry has at least another
100 years of use. However, because the
quarry is nestled in a narrow canyon
on the Front Range of the Rocky
Mountains 50 miles west of Denver, the
existing facility had outgrown the space.
™
Albert Frei worked with a team of experts from Baldor that not only reviewed all the drawings and
specifications, but also helped him select the right products. Frei said it was very comforting getting
help from experts who understand his industry.
“Our biggest handicap is real estate,
which means we can only produce the
amount we can take out in trucks,” says
Albert Frei, Jr., president, Albert Frei
& Sons. “We don’t have the luxury of
space to stockpile material, so during
our peak season, we struggle to keep up
with customer demand. It’s been a real
balancing act.”
With no more room to grow “out,” Frei
realized they would have to grow by
building “up.” With all sorts of design
ideas in his head, he decided in early
2009 to hire engineering firm MA
16 | Solutions Magazine | Number 6
Those fears were quickly put to rest
when Frei began working closely with
Baldor’s System-1 group, a team that
facilitates the design, quotation and
order processing of multiple power
transmission and electrical products into
a complete packaged solution.
Bielski & Associates to help him get all
those ideas down on paper.
The result is something unique in the
industry: an 11-story steel structure
that’s actually three plants in one.
Seemingly endless conveyors bring in
material, where it’s crushed, screened,
diverted, and when it’s the right size,
loaded out.
The unique design of the new crushing plant allows the Walstrum quarry to produce four different products at the same time, and offers the flexibility to produce a total of 12 different products.
“With this design, we have the ability
to make four different products at the
same time,” explains Frei. “And with
a touch of a button, we can change
the type of product. Now we have the
flexibility to easily make 12 different
products, which is going to allow us to
give the customers exactly what they
want, with costs that will be more than
competitive.”
With his desire to build a plant
that will last for the next 60 to 70
years, Frei wasn’t looking to buy the
cheapest products; instead, he wanted
“By working with Baldor’s System-1
group and getting them to do this as
a complete package, it really helped
me with the cost,” explains Frei. “I
was so pleased that I was able to get
exactly the products I wanted. But more
importantly, because of their design
expertise, the System-1 group also
helped me select the right equipment,
plus they worked closely with my
engineer and conveyor manufacturer
to make sure that we had no issues at
installation or start-up.”
Number 6 | Solutions Magazine | 17
F e at u r e s
F e at u r e s
“In my world,
Baldor•Dodge products
are the best of the best.
All the products are built
tough, from gearing to
bearings, to the heavyduty pulleys.”
Albert Frei, Jr., president,
Albert Frei & Sons
products with proven performance
and dependability. And since he had a
wealth of experience with Baldor•Dodge
Torque-Arm gearing, the choice for all
the mechanical products was clear.
™
“In my world, Baldor•Dodge products
are the best of the best,” exclaims Frei.
“All the products are built tough, and
you can get everything you need, from
gearing to bearings, to the heavy-duty
pulleys. These were exactly the products
I wanted, but my fear was I wouldn’t be
able to afford what I see as the top of
the line.”
With Albert Frei’s desire to build a plant that will last for the next 60 to 70 years, he wasn’t looking to buy the cheapest products. Instead, he wanted products
with proven performance and dependability. For Frei, that meant choosing Baldor•Dodge® mechanical products and Baldor•Reliance® motors.
In 1982, the family opened their
Walstrum facility, a large-capacity
granite quarry. With more than 1,800
acres, the quarry has at least another
100 years of use. However, because the
quarry is nestled in a narrow canyon
on the Front Range of the Rocky
Mountains 50 miles west of Denver, the
existing facility had outgrown the space.
™
Albert Frei worked with a team of experts from Baldor that not only reviewed all the drawings and
specifications, but also helped him select the right products. Frei said it was very comforting getting
help from experts who understand his industry.
“Our biggest handicap is real estate,
which means we can only produce the
amount we can take out in trucks,” says
Albert Frei, Jr., president, Albert Frei
& Sons. “We don’t have the luxury of
space to stockpile material, so during
our peak season, we struggle to keep up
with customer demand. It’s been a real
balancing act.”
With no more room to grow “out,” Frei
realized they would have to grow by
building “up.” With all sorts of design
ideas in his head, he decided in early
2009 to hire engineering firm MA
16 | Solutions Magazine | Number 6
Those fears were quickly put to rest
when Frei began working closely with
Baldor’s System-1 group, a team that
facilitates the design, quotation and
order processing of multiple power
transmission and electrical products into
a complete packaged solution.
Bielski & Associates to help him get all
those ideas down on paper.
The result is something unique in the
industry: an 11-story steel structure
that’s actually three plants in one.
Seemingly endless conveyors bring in
material, where it’s crushed, screened,
diverted, and when it’s the right size,
loaded out.
The unique design of the new crushing plant allows the Walstrum quarry to produce four different products at the same time, and offers the flexibility to produce a total of 12 different products.
“With this design, we have the ability
to make four different products at the
same time,” explains Frei. “And with
a touch of a button, we can change
the type of product. Now we have the
flexibility to easily make 12 different
products, which is going to allow us to
give the customers exactly what they
want, with costs that will be more than
competitive.”
With his desire to build a plant
that will last for the next 60 to 70
years, Frei wasn’t looking to buy the
cheapest products; instead, he wanted
“By working with Baldor’s System-1
group and getting them to do this as
a complete package, it really helped
me with the cost,” explains Frei. “I
was so pleased that I was able to get
exactly the products I wanted. But more
importantly, because of their design
expertise, the System-1 group also
helped me select the right equipment,
plus they worked closely with my
engineer and conveyor manufacturer
to make sure that we had no issues at
installation or start-up.”
Number 6 | Solutions Magazine | 17
F e at u r e s
F e at u r e s
caption
Originally, Albert Frei selected standard efficient motors for the project, but when Baldor talked with him about the energy rebate program offered by the local
energy provider, he was thrilled with the opportunity to upgrade and install Baldor•Reliance severe duty premium efficient motors.
Frei received additional design
assistance from Baldor’s aggregate
Industry Solutions team, a group
dedicated to working directly with
aggregate producers. He also had the
support of the local Baldor•Dodge
field sales engineer, who Frei says not
only spent a lot of time on-site, but
was always available to answer any of
his questions. With all of this help and
support, Frei says he was confident the
project would be a success.
The three Baldor•Reliance 500 HP motors on the Metso crushers were designed by Baldor to be a more energy efficient NEMA Design C torque curve motor.
According to Albert Frei, Baldor was the only motor manufacturer willing to help him with an energy efficient design so he could qualify for energy rebates
being offered by his local utility.
18 | Solutions Magazine | Number 6
“Everyone I worked with from Baldor
knew what they were doing in this
industry, and they understood what I
needed,” comments Frei. “They looked
over all the drawings and specifications,
making sure I was doing everything I
needed to do. It was very comforting
getting this kind of help from experts
who work in this field every day.”
With one touch of a button, quarry operator Tommy Frei can change the type of product being
produced at the plant.
Number 6 | Solutions Magazine | 19
F e at u r e s
F e at u r e s
caption
Originally, Albert Frei selected standard efficient motors for the project, but when Baldor talked with him about the energy rebate program offered by the local
energy provider, he was thrilled with the opportunity to upgrade and install Baldor•Reliance severe duty premium efficient motors.
Frei received additional design
assistance from Baldor’s aggregate
Industry Solutions team, a group
dedicated to working directly with
aggregate producers. He also had the
support of the local Baldor•Dodge
field sales engineer, who Frei says not
only spent a lot of time on-site, but
was always available to answer any of
his questions. With all of this help and
support, Frei says he was confident the
project would be a success.
The three Baldor•Reliance 500 HP motors on the Metso crushers were designed by Baldor to be a more energy efficient NEMA Design C torque curve motor.
According to Albert Frei, Baldor was the only motor manufacturer willing to help him with an energy efficient design so he could qualify for energy rebates
being offered by his local utility.
18 | Solutions Magazine | Number 6
“Everyone I worked with from Baldor
knew what they were doing in this
industry, and they understood what I
needed,” comments Frei. “They looked
over all the drawings and specifications,
making sure I was doing everything I
needed to do. It was very comforting
getting this kind of help from experts
who work in this field every day.”
With one touch of a button, quarry operator Tommy Frei can change the type of product being
produced at the plant.
Number 6 | Solutions Magazine | 19
F e at u r e s
F e at u r e s
Frei wanted to find a way to get a more
efficient product.
“Baldor was the only motor
manufacturer willing to help me with
getting a more efficient Design C
motor so I could qualify for energy
rebates,” says Frei. “Baldor engineers
modified the electrical design of the
motor to improve the efficiency, and
while it’s not NEMA Premium, it’s
still the most efficient Design C motor
available. Baldor made it possible for
me to get a portion of the rebate,
which adds up to thousands of dollars –
plus the energy savings I’ll get over the
life of these 500 HP motors is going to
be huge.”
The energy savings story will continue
as Frei plans to replace all the
existing motors in the quarry with
Baldor•Reliance premium efficient
designs. He says the task will be made
much easier because the local Baldor
district office, Rocky Mountain-Baldor
located in Denver, stocks all the motors
so they’ll always be on hand when he
needs them.
Albert Frei wanted to install motors that were going to last a long time. That’s why he chose Baldor•Reliance motors, which he says are heavy-duty and well
built. These 50 HP motors with a NEMA Design C torque curve were designed by Baldor engineers to be more energy efficient than standard Design C
motors on the market.
Frei’s grandfather started the company
in a gravel pit with a small cone
crusher and a 5' by 10' screen deck.
Albert Frei, Sr., built on his dad’s
success and handed a thriving business
over to his son. Frei, Jr., believes he and
his brothers have carried on the family
legacy by building something that can
be passed on to the next generation. It's
an investment Frei believes will pay off.
“This project’s success is due in large part to the
Baldor team that helped me every step of the way. If
I had to do it all over again, I wouldn’t hesitate, and
I wouldn’t change a thing.”
Albert Frei, Jr., president, Albert Frei & Sons
When it came to choosing motors, Frei
maintained his philosophy of installing
the best product available, and that
meant choosing USA-manufactured
Baldor•Reliance motors for the reducer
packages powering all of the conveyors.
Originally, he selected a standard
efficient motor, but when Baldor talked
with him about the energy rebate
program offered by the local energy
provider, Xcel Energy Colorado, he
was thrilled with the opportunity to upgrade his motor choice.
®
20 | Solutions Magazine | Number 6
“The willingness of Baldor to help me
understand the rebate program and
how to use all the right codes made
it possible for me to install NEMA
Premium motors throughout the
plant,” says Frei. “I wanted motors
that were going to last a long time,
and that’s what I’ve got with these
Baldor•Reliance severe duty premium
efficient motors. These motors are
heavy-duty and well built. Not only do I
get the energy rebate, which offsets the
cost of the more efficient motor, I will
Both the Baldor•Dodge Mine Duty Extra wing pulleys (lower) and Mine Duty Extra drum pulleys
(upper) use a thick, integral, one-piece hub design, eliminating the hub to end-disc weld, which is the
most common failure point on a conveyor pulley. Albert Frei calls these pulleys rugged and tough.
®
also enjoy the energy savings for the life
of the motor.”
By selecting the Torque-Arm II gearbox, Albert
Frei says he was able to downsize and save money,
while still getting the power needed for the
application.
The partnership between Frei and the
Baldor team continued to strengthen
as he looked at motor selection for two
specific applications in the plant: 500
HP motors for each of the three Metso
crushers, and the six 50 HP motors on
the three Deister Quad deck screens.
Both of these applications require
motors designed with a NEMA Design
C torque curve, which provides a higher
starting torque for high inertia loads.
These are standard efficient motors,
but with rebate money on the table,
“I designed this plant to last,” says Frei.
“That’s how I built it, and that’s how
I chose the products to put in it. My
dream became a vision, and my vision
is now reality. This project’s success is
due in large part to the Baldor team
that helped me every step of the way. If
I had to do it all over again, I wouldn’t
hesitate, and I wouldn’t change a
thing.”
Number 6 | Solutions Magazine | 21
F e at u r e s
F e at u r e s
Frei wanted to find a way to get a more
efficient product.
“Baldor was the only motor
manufacturer willing to help me with
getting a more efficient Design C
motor so I could qualify for energy
rebates,” says Frei. “Baldor engineers
modified the electrical design of the
motor to improve the efficiency, and
while it’s not NEMA Premium, it’s
still the most efficient Design C motor
available. Baldor made it possible for
me to get a portion of the rebate,
which adds up to thousands of dollars –
plus the energy savings I’ll get over the
life of these 500 HP motors is going to
be huge.”
The energy savings story will continue
as Frei plans to replace all the
existing motors in the quarry with
Baldor•Reliance premium efficient
designs. He says the task will be made
much easier because the local Baldor
district office, Rocky Mountain-Baldor
located in Denver, stocks all the motors
so they’ll always be on hand when he
needs them.
Albert Frei wanted to install motors that were going to last a long time. That’s why he chose Baldor•Reliance motors, which he says are heavy-duty and well
built. These 50 HP motors with a NEMA Design C torque curve were designed by Baldor engineers to be more energy efficient than standard Design C
motors on the market.
Frei’s grandfather started the company
in a gravel pit with a small cone
crusher and a 5' by 10' screen deck.
Albert Frei, Sr., built on his dad’s
success and handed a thriving business
over to his son. Frei, Jr., believes he and
his brothers have carried on the family
legacy by building something that can
be passed on to the next generation. It's
an investment Frei believes will pay off.
“This project’s success is due in large part to the
Baldor team that helped me every step of the way. If
I had to do it all over again, I wouldn’t hesitate, and
I wouldn’t change a thing.”
Albert Frei, Jr., president, Albert Frei & Sons
When it came to choosing motors, Frei
maintained his philosophy of installing
the best product available, and that
meant choosing USA-manufactured
Baldor•Reliance motors for the reducer
packages powering all of the conveyors.
Originally, he selected a standard
efficient motor, but when Baldor talked
with him about the energy rebate
program offered by the local energy
provider, Xcel Energy Colorado, he
was thrilled with the opportunity to upgrade his motor choice.
®
20 | Solutions Magazine | Number 6
“The willingness of Baldor to help me
understand the rebate program and
how to use all the right codes made
it possible for me to install NEMA
Premium motors throughout the
plant,” says Frei. “I wanted motors
that were going to last a long time,
and that’s what I’ve got with these
Baldor•Reliance severe duty premium
efficient motors. These motors are
heavy-duty and well built. Not only do I
get the energy rebate, which offsets the
cost of the more efficient motor, I will
Both the Baldor•Dodge Mine Duty Extra wing pulleys (lower) and Mine Duty Extra drum pulleys
(upper) use a thick, integral, one-piece hub design, eliminating the hub to end-disc weld, which is the
most common failure point on a conveyor pulley. Albert Frei calls these pulleys rugged and tough.
®
also enjoy the energy savings for the life
of the motor.”
By selecting the Torque-Arm II gearbox, Albert
Frei says he was able to downsize and save money,
while still getting the power needed for the
application.
The partnership between Frei and the
Baldor team continued to strengthen
as he looked at motor selection for two
specific applications in the plant: 500
HP motors for each of the three Metso
crushers, and the six 50 HP motors on
the three Deister Quad deck screens.
Both of these applications require
motors designed with a NEMA Design
C torque curve, which provides a higher
starting torque for high inertia loads.
These are standard efficient motors,
but with rebate money on the table,
“I designed this plant to last,” says Frei.
“That’s how I built it, and that’s how
I chose the products to put in it. My
dream became a vision, and my vision
is now reality. This project’s success is
due in large part to the Baldor team
that helped me every step of the way. If
I had to do it all over again, I wouldn’t
hesitate, and I wouldn’t change a
thing.”
Number 6 | Solutions Magazine | 21
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