Solutions Magazine

Solutions Magazine
solutions
PRSRT STD
US POSTAGE
PAID
Little Rock, AR
Permit No. 175
A Publication Featuring Baldor Electric Company Products
Number 6
magazine
Built
to Last...
Albert Frei & Sons
Choose Baldor Products
for Crushing Plant
Expansion
World Headquarters
P.O. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1) 479.646.4711, Fax: (1) 479.648.5792, International Fax: (1) 479.648.5895
baldor.com
©2010 Baldor Electric Company
Solutions1010
All Rights Reserved. Printed in USA.
10/10-AG-13M
Pl u s
A Packaged Solution from Baldor
A Trusted Partnership
Helps an Ohio Wastewater Treatment Plant Save Money
Leads to Success in the Iron Range
caption
Invest in Gold
Cover: PG 14
Contents
Solutions Magazine
Number 6
Featuring Baldor•Reliance® & Baldor•Dodge® Products
baldor.com
2 Briefings
4 A packaged Solution from Baldor
Helps an Ohio Wastewater Treatment Plant Save Money
10 Baldor Assists Australian Company
to Develop Low-Cost Solar Cell Technology
14 Built to Last...
Albert Frei & Sons Choose Baldor Products for Crushing Plant Expansion
22 A Trusted Partnership
Leads to Success in the Iron Range
Electric motors consume 63 percent of all electricity used
in U.S. industry. Designed and built to meet or exceed
NEMA Premium® efficiency standards, Baldor•Reliance®
Super-E® motors run cooler, last longer and cost less every
minute they operate.
• Energy Efficient
• Unmatched Quality
Fractional to 15,000 Hp, Baldor•Reliance Super-E
motors reduce your electricity costs with a return on your
investment that’s as good as gold.
• Superior Reliability
baldor.com
• Quickest Delivery Available
479-646-4711
28 New Road-Going Trommel
Uses Baldor•Dodge Bearings to Simplify On-Site Maintenance
Baldor’s mission is to be the best (as determined by our
customers) marketers, designers and manufacturers
of industrial electric motors, mechanical power
transmission products, drives and generators.
©2010 Baldor Electric Company
Solutions Magazine is published by the Marketing Communications Department of Baldor Electric Company.
For more information, please contact [email protected]
baldor.com
caption
Invest in Gold
Cover: PG 14
Contents
Solutions Magazine
Number 6
Featuring Baldor•Reliance® & Baldor•Dodge® Products
baldor.com
2 Briefings
4 A packaged Solution from Baldor
Helps an Ohio Wastewater Treatment Plant Save Money
10 Baldor Assists Australian Company
to Develop Low-Cost Solar Cell Technology
14 Built to Last...
Albert Frei & Sons Choose Baldor Products for Crushing Plant Expansion
22 A Trusted Partnership
Leads to Success in the Iron Range
Electric motors consume 63 percent of all electricity used
in U.S. industry. Designed and built to meet or exceed
NEMA Premium® efficiency standards, Baldor•Reliance®
Super-E® motors run cooler, last longer and cost less every
minute they operate.
• Energy Efficient
• Unmatched Quality
Fractional to 15,000 Hp, Baldor•Reliance Super-E
motors reduce your electricity costs with a return on your
investment that’s as good as gold.
• Superior Reliability
baldor.com
• Quickest Delivery Available
479-646-4711
28 New Road-Going Trommel
Uses Baldor•Dodge Bearings to Simplify On-Site Maintenance
Baldor’s mission is to be the best (as determined by our
customers) marketers, designers and manufacturers
of industrial electric motors, mechanical power
transmission products, drives and generators.
©2010 Baldor Electric Company
Solutions Magazine is published by the Marketing Communications Department of Baldor Electric Company.
For more information, please contact [email protected]
baldor.com
B r ie f i n g s
Briefings
Baldor Introduces Two New Dirty Duty Drives
The new Baldor Dirty Duty NEMA
4X VS1SP and VS1GV drives provide
the perfect mix of performance and
enclosure integrity for demanding
applications in tough environments.
Both drives are simple to program and
easy to operate. A user-friendly keypad
with familiar up and down keys, along
with left and right arrows, allows for
effortless navigation and parameter
changes. Multiple English-text status
screens are easy to read on the fullgraphics backlit display. An optional
external keypad may be remote mounted
up to 200 feet from the drive.
Utilizing Baldor’s popular H2 inverter
and vector technologies, both drives
are designed to perform in the most
challenging applications. The VS1SP
models are configured for open-loop/
sensorless vector applications, while
the VS1GV models are designed for
the more demanding closed loop
vector applications. Both models utilize
a robust NEMA 4X enclosure that
can handle dusty/dirty environments
or even high-pressure washdown
applications. Dirty Duty drives are rated
IP66 and can withstand up to 1000 PSI.
The quick-ship program initially covers
motors:
• 200 HP through 700 HP
• 449 through 5000 frames
• TEFC
• 2, 4 and 6 pole
• 2300/4000 volt, form wound
• 460 or 575 volt, random wound
• 3 phase, 60 hertz
• 1.0 service factor, Class B rise
• 1.15 service factor, Class F rise
• Anti-friction bearings for coupled
or belted duty
2 | Solutions Magazine | Number 6
Baldor has recently added designs to
its Baldor•Reliance Super-E line of
premium efficient motors.
®
Originally introduced in 1983, Super-E
motors have consistently delivered
some of the motor industry’s highest
efficiencies and energy savings. Super-E
efficiencies meet or exceed NEMA
Premium efficiency standards, and
™
Baldor VS1SP and VS1GV Dirty
Duty NEMA 4X AC drives offer USB
standard interface for Mint WorkBench
tools and have multiple communication
and expansion option boards.
Baldor Launches Quick-Ship Program
Continuing its tradition of providing
superior customer service, Baldor has
launched a large AC motor quick-ship
program that offers custom above
NEMA AC motors in two weeks.
Now, customers can choose from a
broad list of design options to build a
custom motor that fits their application
requirements. Baldor will ship that
motor within two weeks from the date
the order was received. This builds on
Baldor’s large inventory of in-stock
full-featured above NEMA AC motors
through 1,500 HP.
Baldor Expands Super-E® Motor Line
for
New Baldor•Reliance Super-E motors
include 26 premium efficient ratings
designed for heating, ventilation and
the air conditioning industry; over 50
washdown, paint-free and all-stainless
premium efficient ratings; and
over 70 premium efficient
unit handling ratings.
Baldor is also adding
450 new Super-E
designs across many AC
motor families to solidify
its commitment to offer the
broadest line of NEMA Premium
motors available in the industry.
Baldor•Reliance Super-E premium
efficient motors carry a full three-year
warranty. General purpose ratings are
available from stock from 1 to 450
HP. Baldor also stocks Super-E severe
duty motors up to 700 HP in low and
medium voltages, C-Face to 100 HP,
explosion-proof through 200 HP and
close-coupled pump ratings up to 50
HP.
The wide range of stock Super-E
designs includes washdown duty, IEEE
841 severe duty, 200 and 575 volt, brake
motors and open drip proof through
450 HP. In addition, Baldor•Reliance
premium efficiency custom motors are
available through 15,000 HP.
Large AC Motors
Customers can also choose from a long
list of popular options to add to their
motor selection, including winding
RTDs, vibration detection, space
heaters, shaft modifications and
Inpro/Seal bearing isolators. See our
FL435 flyer for all the details.
®
meet or exceed levels required by the
Energy Independence and Security Act,
which will go into effect in December
2010. Now, with the latest additions,
Super-E motors will be available in
almost any configuration for specific
applications.
Time-proven designs make it possible
for Baldor•Reliance large AC motors
to deliver outstanding performance
and exceptional value. FlexFlow
manufacturing and a dedication to
quality make it possible for Baldor
to build custom motors in two weeks
and still maintain reliability in critical
applications. Visit baldor.com to learn
more about the large AC motor quickship program, and our complete line
of above NEMA AC motors through
15,000 HP.
®
Baldor Wins Order
for
Toromocho Copper Project
Baldor has won the order to supply
six Baldor•Dodge 2,500K CSTs
(Controlled Start Transmissions) to
power conveyors at the new Toromocho
copper mine in Peru. FLSmidth, the
material handling EPC firm supplying
the overland conveyors for the project,
has purchased six CST packages with
input and output couplings that include
a unique spacer coupling design, highspeed brakes and bases. Located 86
miles from Lima, Peru, the mine sits at
14,000 feet and is expected to become
one of the most productive copper
mines in the world.
®
“The proven performance of CSTs
installed around the world in some of
the toughest mining applications is the
reason Baldor won this order,” said Len
Eros, Baldor’s mining industry manager.
“This gear reducer is engineered to
deliver a smooth, controlled start for
difficult high inertia loads, like the
long conveyors that will be used on
this project. Since the units will
operate at 16,500
feet, the CST is
also the best
choice because
its design can
be easily
modified to
compensate
for issues
related to
high altitude
applications.”
The CST units
will begin shipping
to Peru at the end of
2010. The mine is scheduled to
be online in 2012.
Number 6 | Solutions Magazine | 3
B r ie f i n g s
Briefings
Baldor Introduces Two New Dirty Duty Drives
The new Baldor Dirty Duty NEMA
4X VS1SP and VS1GV drives provide
the perfect mix of performance and
enclosure integrity for demanding
applications in tough environments.
Both drives are simple to program and
easy to operate. A user-friendly keypad
with familiar up and down keys, along
with left and right arrows, allows for
effortless navigation and parameter
changes. Multiple English-text status
screens are easy to read on the fullgraphics backlit display. An optional
external keypad may be remote mounted
up to 200 feet from the drive.
Utilizing Baldor’s popular H2 inverter
and vector technologies, both drives
are designed to perform in the most
challenging applications. The VS1SP
models are configured for open-loop/
sensorless vector applications, while
the VS1GV models are designed for
the more demanding closed loop
vector applications. Both models utilize
a robust NEMA 4X enclosure that
can handle dusty/dirty environments
or even high-pressure washdown
applications. Dirty Duty drives are rated
IP66 and can withstand up to 1000 PSI.
The quick-ship program initially covers
motors:
• 200 HP through 700 HP
• 449 through 5000 frames
• TEFC
• 2, 4 and 6 pole
• 2300/4000 volt, form wound
• 460 or 575 volt, random wound
• 3 phase, 60 hertz
• 1.0 service factor, Class B rise
• 1.15 service factor, Class F rise
• Anti-friction bearings for coupled
or belted duty
2 | Solutions Magazine | Number 6
Baldor has recently added designs to
its Baldor•Reliance Super-E line of
premium efficient motors.
®
Originally introduced in 1983, Super-E
motors have consistently delivered
some of the motor industry’s highest
efficiencies and energy savings. Super-E
efficiencies meet or exceed NEMA
Premium efficiency standards, and
™
Baldor VS1SP and VS1GV Dirty
Duty NEMA 4X AC drives offer USB
standard interface for Mint WorkBench
tools and have multiple communication
and expansion option boards.
Baldor Launches Quick-Ship Program
Continuing its tradition of providing
superior customer service, Baldor has
launched a large AC motor quick-ship
program that offers custom above
NEMA AC motors in two weeks.
Now, customers can choose from a
broad list of design options to build a
custom motor that fits their application
requirements. Baldor will ship that
motor within two weeks from the date
the order was received. This builds on
Baldor’s large inventory of in-stock
full-featured above NEMA AC motors
through 1,500 HP.
Baldor Expands Super-E® Motor Line
for
New Baldor•Reliance Super-E motors
include 26 premium efficient ratings
designed for heating, ventilation and
the air conditioning industry; over 50
washdown, paint-free and all-stainless
premium efficient ratings; and
over 70 premium efficient
unit handling ratings.
Baldor is also adding
450 new Super-E
designs across many AC
motor families to solidify
its commitment to offer the
broadest line of NEMA Premium
motors available in the industry.
Baldor•Reliance Super-E premium
efficient motors carry a full three-year
warranty. General purpose ratings are
available from stock from 1 to 450
HP. Baldor also stocks Super-E severe
duty motors up to 700 HP in low and
medium voltages, C-Face to 100 HP,
explosion-proof through 200 HP and
close-coupled pump ratings up to 50
HP.
The wide range of stock Super-E
designs includes washdown duty, IEEE
841 severe duty, 200 and 575 volt, brake
motors and open drip proof through
450 HP. In addition, Baldor•Reliance
premium efficiency custom motors are
available through 15,000 HP.
Large AC Motors
Customers can also choose from a long
list of popular options to add to their
motor selection, including winding
RTDs, vibration detection, space
heaters, shaft modifications and
Inpro/Seal bearing isolators. See our
FL435 flyer for all the details.
®
meet or exceed levels required by the
Energy Independence and Security Act,
which will go into effect in December
2010. Now, with the latest additions,
Super-E motors will be available in
almost any configuration for specific
applications.
Time-proven designs make it possible
for Baldor•Reliance large AC motors
to deliver outstanding performance
and exceptional value. FlexFlow
manufacturing and a dedication to
quality make it possible for Baldor
to build custom motors in two weeks
and still maintain reliability in critical
applications. Visit baldor.com to learn
more about the large AC motor quickship program, and our complete line
of above NEMA AC motors through
15,000 HP.
®
Baldor Wins Order
for
Toromocho Copper Project
Baldor has won the order to supply
six Baldor•Dodge 2,500K CSTs
(Controlled Start Transmissions) to
power conveyors at the new Toromocho
copper mine in Peru. FLSmidth, the
material handling EPC firm supplying
the overland conveyors for the project,
has purchased six CST packages with
input and output couplings that include
a unique spacer coupling design, highspeed brakes and bases. Located 86
miles from Lima, Peru, the mine sits at
14,000 feet and is expected to become
one of the most productive copper
mines in the world.
®
“The proven performance of CSTs
installed around the world in some of
the toughest mining applications is the
reason Baldor won this order,” said Len
Eros, Baldor’s mining industry manager.
“This gear reducer is engineered to
deliver a smooth, controlled start for
difficult high inertia loads, like the
long conveyors that will be used on
this project. Since the units will
operate at 16,500
feet, the CST is
also the best
choice because
its design can
be easily
modified to
compensate
for issues
related to
high altitude
applications.”
The CST units
will begin shipping
to Peru at the end of
2010. The mine is scheduled to
be online in 2012.
Number 6 | Solutions Magazine | 3
F e at u r e s
A Packaged Solution
F e at u r e s
from
Baldor
Helps an Ohio
Wastewater Treatment Plant
SAVE MONEY
M
ost of us don’t think about what happens when we flush the toilet, pop the
bathtub drain or run the dishwasher. But all that wastewater has to go
somewhere. If you are a resident in Maineville, Ohio, that “somewhere” is
the Lower Little Miami Wastewater Treatment Plant.
4 | Solutions Magazine | Number 5
Number 5 | Solutions Magazine | 5
F e at u r e s
A Packaged Solution
F e at u r e s
from
Baldor
Helps an Ohio
Wastewater Treatment Plant
SAVE MONEY
M
ost of us don’t think about what happens when we flush the toilet, pop the
bathtub drain or run the dishwasher. But all that wastewater has to go
somewhere. If you are a resident in Maineville, Ohio, that “somewhere” is
the Lower Little Miami Wastewater Treatment Plant.
4 | Solutions Magazine | Number 5
Number 5 | Solutions Magazine | 5
f e at u r e s
F e at u r e s
“Because of System-1, I didn’t have to try to source all of these different
pieces of equipment and then worry about how to put them all together.
The whole package works as a system, making it simple for us.”
Dave Walling, deputy sanitary engineer,
Warren County Water and Sewer Department
not in the firm’s original scope of work,
Malcolm Pirnie’s project engineer, Erik
Torgersen, offered his help to ensure
the work on the VLR was a success.
“Dave and Brian contacted me, and
I was more than willing to share
information,” says Torgersen. “Most of
the time, plant officials will go back to
the company that put in the original
equipment, but this can be expensive.
Warren County was willing to break
that mold and work with Baldor, and I
was happy to help.”
With all of the information gathered, it
was then up to Baldor’s System-1
group to engineer the individual
systems. System-1 specializes in
designing, quoting and ordering the
required products in order to deliver
a complete packaged solution to the
customer. Each package designed
for the Lower Little Miami plant
contained a 20 HP Baldor•Reliance
Super-E Severe Duty motor, a size 6
Baldor•Dodge Torque-Arm II reducer
and two Baldor•Dodge Imperial
bearings. The motor and reducer
packages arrived on-site pre-assembled
and ready to install.
™
When equipment needed to be replaced on the existing Vertical Loop Reactors (VLRs) at the Lower Little Miami Wastewater Treatment Plant, Warren County
officials chose Baldor equipment. VLRs are an aerobic biological treatment process that utilizes large discs that are continually rotated to move wastewater and
impart oxygen for aeration.
The purification of wastewater is
important in any community, but it’s
especially critical at this plant because
it releases the treated water back into a
state and national scenic river, the Little
Miami River. Because of the river’s
protected status, the plant must meet
the Ohio Environmental Protection
Agency’s most stringent standards.
A major expansion is currently under
way at the treatment plant, which will
nearly double its capacity. Dave Walling,
the deputy sanitary engineer for the
Warren County Water and Sewer
Department, not only monitors the
expansion project, but was also recently
tasked with replacing equipment on one
of the existing Vertical Loop Reactors
(VLRs) that was built in the 1990s.
6 | Solutions Magazine | Number 6
A VLR is an aerobic biological
treatment process that utilizes large
discs that are continually rotated to
move wastewater and impart oxygen
for aeration. In this system, wastewater
passes through a chain of four
rectangular concrete tanks, each having
two rotating shafts for a total of eight
units. Each of the eight VLR shafts has
two bearings, and a motor/reducer drive
package.
I wanted a package, which is what they
were offering, but wanted to see if I
could work with someone locally and
find a more affordable solution.”
®
®
™
™
With a phone call, Walling was able
to find the local help he needed, along
with a package that included products
with a brand name he knew and trusted.
“Dave Marsh with Kaman Industrial
Technologies, and Brian Fields, a
Baldor•Dodge field sales engineer,
visited me at the plant and did an onsite inspection – really studying the
application so they understood what we
needed,” explains Walling.
®
When one of the shafts and an entire
assembly broke apart, Walling realized
that repair was no longer an option.
“Clearly, the equipment had reached the
end of its useful life, so we decided to
upgrade and replace the shafts, bearings,
motors and gearboxes on all four
tanks,” says Walling. “But when we got
the price from an OEM to supply the
equipment, it was very expensive.
The team received additional help from
Malcolm Pirnie, the environmental
engineering consulting firm in charge
of the expansion project. While
problems with the existing tank were
Baldor’s System-1 group engineered a complete packaged solution for the Lower Little Miami Wastewater
Treatment Plant. Each package contained a 20 HP Baldor•Reliance Super-E Severe Duty motor, a size 6
Baldor•Dodge Torque-Arm II reducer and two Baldor•Dodge Imperial bearings. The motor and reducer
packages arrived on-site pre-assembled and ready to install.
“Because of System-1, I didn’t have to
try to source all of these different pieces
of equipment and then worry about
how to put them all together,” says
Walling. “The whole package works as
a system, making it simple for us. I have
one source of contact if I ever have any
questions, plus I have the local support,
which is really important to us.”
Number 6 | Solutions Magazine | 7
f e at u r e s
F e at u r e s
“Because of System-1, I didn’t have to try to source all of these different
pieces of equipment and then worry about how to put them all together.
The whole package works as a system, making it simple for us.”
Dave Walling, deputy sanitary engineer,
Warren County Water and Sewer Department
not in the firm’s original scope of work,
Malcolm Pirnie’s project engineer, Erik
Torgersen, offered his help to ensure
the work on the VLR was a success.
“Dave and Brian contacted me, and
I was more than willing to share
information,” says Torgersen. “Most of
the time, plant officials will go back to
the company that put in the original
equipment, but this can be expensive.
Warren County was willing to break
that mold and work with Baldor, and I
was happy to help.”
With all of the information gathered, it
was then up to Baldor’s System-1
group to engineer the individual
systems. System-1 specializes in
designing, quoting and ordering the
required products in order to deliver
a complete packaged solution to the
customer. Each package designed
for the Lower Little Miami plant
contained a 20 HP Baldor•Reliance
Super-E Severe Duty motor, a size 6
Baldor•Dodge Torque-Arm II reducer
and two Baldor•Dodge Imperial
bearings. The motor and reducer
packages arrived on-site pre-assembled
and ready to install.
™
When equipment needed to be replaced on the existing Vertical Loop Reactors (VLRs) at the Lower Little Miami Wastewater Treatment Plant, Warren County
officials chose Baldor equipment. VLRs are an aerobic biological treatment process that utilizes large discs that are continually rotated to move wastewater and
impart oxygen for aeration.
The purification of wastewater is
important in any community, but it’s
especially critical at this plant because
it releases the treated water back into a
state and national scenic river, the Little
Miami River. Because of the river’s
protected status, the plant must meet
the Ohio Environmental Protection
Agency’s most stringent standards.
A major expansion is currently under
way at the treatment plant, which will
nearly double its capacity. Dave Walling,
the deputy sanitary engineer for the
Warren County Water and Sewer
Department, not only monitors the
expansion project, but was also recently
tasked with replacing equipment on one
of the existing Vertical Loop Reactors
(VLRs) that was built in the 1990s.
6 | Solutions Magazine | Number 6
A VLR is an aerobic biological
treatment process that utilizes large
discs that are continually rotated to
move wastewater and impart oxygen
for aeration. In this system, wastewater
passes through a chain of four
rectangular concrete tanks, each having
two rotating shafts for a total of eight
units. Each of the eight VLR shafts has
two bearings, and a motor/reducer drive
package.
I wanted a package, which is what they
were offering, but wanted to see if I
could work with someone locally and
find a more affordable solution.”
®
®
™
™
With a phone call, Walling was able
to find the local help he needed, along
with a package that included products
with a brand name he knew and trusted.
“Dave Marsh with Kaman Industrial
Technologies, and Brian Fields, a
Baldor•Dodge field sales engineer,
visited me at the plant and did an onsite inspection – really studying the
application so they understood what we
needed,” explains Walling.
®
When one of the shafts and an entire
assembly broke apart, Walling realized
that repair was no longer an option.
“Clearly, the equipment had reached the
end of its useful life, so we decided to
upgrade and replace the shafts, bearings,
motors and gearboxes on all four
tanks,” says Walling. “But when we got
the price from an OEM to supply the
equipment, it was very expensive.
The team received additional help from
Malcolm Pirnie, the environmental
engineering consulting firm in charge
of the expansion project. While
problems with the existing tank were
Baldor’s System-1 group engineered a complete packaged solution for the Lower Little Miami Wastewater
Treatment Plant. Each package contained a 20 HP Baldor•Reliance Super-E Severe Duty motor, a size 6
Baldor•Dodge Torque-Arm II reducer and two Baldor•Dodge Imperial bearings. The motor and reducer
packages arrived on-site pre-assembled and ready to install.
“Because of System-1, I didn’t have to
try to source all of these different pieces
of equipment and then worry about
how to put them all together,” says
Walling. “The whole package works as
a system, making it simple for us. I have
one source of contact if I ever have any
questions, plus I have the local support,
which is really important to us.”
Number 6 | Solutions Magazine | 7
F e at u r e s
F e at u r e s
Warren County Deputy Sanitary Engineer Dave Walling calls the Baldor•Dodge Imperial bearing a much
improved solution over the setscrew-type bearings they had been using. The Imperial’s concentric grip
holds the shaft tightly without causing any fretting corrosion. Walling says it’s nice to know that they won’t
have to repair or replace these shafts ever again.
piece of the package, Baldor•Reliance
Super-E motors, Walling says he has
never had any doubts about their
performance.
“We have used Baldor•Reliance motors
throughout the rest of the plant, and
I know they are bulletproof and last
forever,” says Walling. “These motors
have proven they can perform in this
harsh environment. Plus, with the
premium efficient design, we’ll enjoy
lower energy costs for the life of the
motors.”
Plant officials describe the Baldor•Dodge Torque-Arm II gear reducer as robust and worry-free. Because of its design, the gearbox runs cooler, which contributes
to a long and reliable life.
More than the Package –
It’s the Performance of the
Products
While Walling was pleased with the
System-1 packaged solution, after two
years in operation, he is equally pleased
with the performance of the products.
He notes that because the Baldor•Dodge
8 | Solutions Magazine | Number 6
Imperial bearings have a concentric
grip, they seem to be holding the shaft
better without causing the fretting
corrosion they dealt with when using
setscrew bearings.
“The Imperial bearing is a much
improved solution for us,” states
Walling. “There’s less vibration, and
we won’t have to worry about setscrews
wearing grooves into the shaft. It’s good
to know that we won’t have to repair or
replace these shafts ever again.”
Walling also describes the
Baldor•Dodge Torque-Arm II gear
reducers as robust and worry-free.
Because of its design, the gearbox runs
cooler, which he believes will lead to a
long and reliable life. As for the final
than that, I believe they got a better
product out of it. I think it’s a more
reliable gear assembly, the bearings
are more durable, the equipment will
be easy to maintain, and the premium
efficient motors will help them save
energy.”
“Baldor's System-1
group can handle the
individual engineered
solution. It saved
Warren County a
substantial amount of
money, but more than
that, I believe they got a
better product out of it.”
Erik Torgersen,
project engineer,
Malcolm Pirnie
Torgersen is also pleased with the
packaged solution and gives credit to
both Kaman and Baldor for getting the
project done quickly. And he believes
that the capabilities of Baldor’s
System-1 group are a great resource for
other wastewater treatment plants that
find themselves in a similar situation.
“Baldor’s System-1 group can handle
the individual engineered solution,” says
Torgersen. “It saved Warren County a
substantial amount of money, but more
The purification of water is important in any community, but it’s especially critical at the Lower Little
Miami Wastewater Treatment Plant because it releases the treated water back into a state and national
scenic river, the Little Miami River. Because of the river’s protected status, the plant must meet the Ohio
Environmental Protection Agency’s most stringent standards.
Number 6 | Solutions Magazine | 9
F e at u r e s
F e at u r e s
Warren County Deputy Sanitary Engineer Dave Walling calls the Baldor•Dodge Imperial bearing a much
improved solution over the setscrew-type bearings they had been using. The Imperial’s concentric grip
holds the shaft tightly without causing any fretting corrosion. Walling says it’s nice to know that they won’t
have to repair or replace these shafts ever again.
piece of the package, Baldor•Reliance
Super-E motors, Walling says he has
never had any doubts about their
performance.
“We have used Baldor•Reliance motors
throughout the rest of the plant, and
I know they are bulletproof and last
forever,” says Walling. “These motors
have proven they can perform in this
harsh environment. Plus, with the
premium efficient design, we’ll enjoy
lower energy costs for the life of the
motors.”
Plant officials describe the Baldor•Dodge Torque-Arm II gear reducer as robust and worry-free. Because of its design, the gearbox runs cooler, which contributes
to a long and reliable life.
More than the Package –
It’s the Performance of the
Products
While Walling was pleased with the
System-1 packaged solution, after two
years in operation, he is equally pleased
with the performance of the products.
He notes that because the Baldor•Dodge
8 | Solutions Magazine | Number 6
Imperial bearings have a concentric
grip, they seem to be holding the shaft
better without causing the fretting
corrosion they dealt with when using
setscrew bearings.
“The Imperial bearing is a much
improved solution for us,” states
Walling. “There’s less vibration, and
we won’t have to worry about setscrews
wearing grooves into the shaft. It’s good
to know that we won’t have to repair or
replace these shafts ever again.”
Walling also describes the
Baldor•Dodge Torque-Arm II gear
reducers as robust and worry-free.
Because of its design, the gearbox runs
cooler, which he believes will lead to a
long and reliable life. As for the final
than that, I believe they got a better
product out of it. I think it’s a more
reliable gear assembly, the bearings
are more durable, the equipment will
be easy to maintain, and the premium
efficient motors will help them save
energy.”
“Baldor's System-1
group can handle the
individual engineered
solution. It saved
Warren County a
substantial amount of
money, but more than
that, I believe they got a
better product out of it.”
Erik Torgersen,
project engineer,
Malcolm Pirnie
Torgersen is also pleased with the
packaged solution and gives credit to
both Kaman and Baldor for getting the
project done quickly. And he believes
that the capabilities of Baldor’s
System-1 group are a great resource for
other wastewater treatment plants that
find themselves in a similar situation.
“Baldor’s System-1 group can handle
the individual engineered solution,” says
Torgersen. “It saved Warren County a
substantial amount of money, but more
The purification of water is important in any community, but it’s especially critical at the Lower Little
Miami Wastewater Treatment Plant because it releases the treated water back into a state and national
scenic river, the Little Miami River. Because of the river’s protected status, the plant must meet the Ohio
Environmental Protection Agency’s most stringent standards.
Number 6 | Solutions Magazine | 9
Baldor Assists
F e at u r e s
F e at u r e s
Australian Company
:to Develop Low-Cost
Solar Cell Technology:
Dyesol is a world leader in the
development of Dye Solar Cell (DSC)
technology, which produces electricity
in a process that utilizes the principles
of nanotechnology and photosynthesis.
DSC technology is particularly efficient
in real-life conditions, such as low
or dappled light, and uses low-cost,
environmentally sustainable materials
together with low-cost, low-energy
manufacturing techniques.
Today, the Dyesol group is focused
on the industrialization and
commercialization of DSC technology
throughout the world, assisting solar
cell manufacturers to develop their own
products, improve cell performance
and develop low-cost mass production
systems.
“There are a number of processes in
the production of a DSC, and it is in
one of these processes that Baldor
motion control technology has proven
so beneficial,” said Anthony Oh,
senior design engineer at Dyesol’s
headquarters in Queanbeyan, New
South Wales, Australia.
“We have used Baldor equipment in
previous designs and have found it to
be very successful. Baldor offers us a
good development platform, a neat
package with proven compatibility
between components, robust design and
worldwide availability and support. Our
clients are located all around the world,
and they are not machine builders, so
we must deliver a ready-to-go, userfriendly package with the necessary
access to support in their region should
it be needed.”
Control network for the Dyesol Die Profiling Machine, including Baldor NextMove e100 motion controller and two Baldor e100 MicroFlex servo drives
networked via Ethernet, EMC filters and power supply.
The DSCs are manufactured by
preparing glass outer skins with a
printed circuit on one side, followed
by a layer of porous titanium dioxide
and application of the dye to the entire
surface. The Dyesol Dye Profiling
Machine, equipped with Baldor motion
control systems, is used to accurately
remove sections of the applied medium
from the glass panel. This results in
multiple individual cells on the glass
panel, joined by the printed circuit. The
cell is completed by vacuum backfilling
with the electrolyte (iodide) and finally
sealing with thermo-plastic, resulting in
a DSC capable of producing an electrical
current.
Anthony Oh, senior design engineer, with a Dyesol Die Profiling Machine, which incorporates a Baldor HMI Panel, a Baldor NextMove® e100 multi-axis motion
controller running Baldor Mint® software, two Baldor MicroFlex servo drives and Baldor BSM brushless servo motors.
10 | Solutions Magazine | Number 6
The latest dye profiling machine
incorporates a Baldor NextMove
e100 multi-axis controller along
Baldor 40R-240MG brushless servo motor with integrated encoder feedback for precise X-axis
positioning of the cleaning head.
Number 6 | Solutions Magazine | 11
Baldor Assists
F e at u r e s
F e at u r e s
Australian Company
:to Develop Low-Cost
Solar Cell Technology:
Dyesol is a world leader in the
development of Dye Solar Cell (DSC)
technology, which produces electricity
in a process that utilizes the principles
of nanotechnology and photosynthesis.
DSC technology is particularly efficient
in real-life conditions, such as low
or dappled light, and uses low-cost,
environmentally sustainable materials
together with low-cost, low-energy
manufacturing techniques.
Today, the Dyesol group is focused
on the industrialization and
commercialization of DSC technology
throughout the world, assisting solar
cell manufacturers to develop their own
products, improve cell performance
and develop low-cost mass production
systems.
“There are a number of processes in
the production of a DSC, and it is in
one of these processes that Baldor
motion control technology has proven
so beneficial,” said Anthony Oh,
senior design engineer at Dyesol’s
headquarters in Queanbeyan, New
South Wales, Australia.
“We have used Baldor equipment in
previous designs and have found it to
be very successful. Baldor offers us a
good development platform, a neat
package with proven compatibility
between components, robust design and
worldwide availability and support. Our
clients are located all around the world,
and they are not machine builders, so
we must deliver a ready-to-go, userfriendly package with the necessary
access to support in their region should
it be needed.”
Control network for the Dyesol Die Profiling Machine, including Baldor NextMove e100 motion controller and two Baldor e100 MicroFlex servo drives
networked via Ethernet, EMC filters and power supply.
The DSCs are manufactured by
preparing glass outer skins with a
printed circuit on one side, followed
by a layer of porous titanium dioxide
and application of the dye to the entire
surface. The Dyesol Dye Profiling
Machine, equipped with Baldor motion
control systems, is used to accurately
remove sections of the applied medium
from the glass panel. This results in
multiple individual cells on the glass
panel, joined by the printed circuit. The
cell is completed by vacuum backfilling
with the electrolyte (iodide) and finally
sealing with thermo-plastic, resulting in
a DSC capable of producing an electrical
current.
Anthony Oh, senior design engineer, with a Dyesol Die Profiling Machine, which incorporates a Baldor HMI Panel, a Baldor NextMove® e100 multi-axis motion
controller running Baldor Mint® software, two Baldor MicroFlex servo drives and Baldor BSM brushless servo motors.
10 | Solutions Magazine | Number 6
The latest dye profiling machine
incorporates a Baldor NextMove
e100 multi-axis controller along
Baldor 40R-240MG brushless servo motor with integrated encoder feedback for precise X-axis
positioning of the cleaning head.
Number 6 | Solutions Magazine | 11
F e at u r e s
F e at u r e s
and high acceleration capabilities in an
ultra-compact body format,” explains
DeSouza. “For the Y-axis, a more
powerful motor was required because
it’s mounted under the table and
incorporates a cogged belt drive to the
spindle. The unit came from our range
of C-series motors, which use our ‘Ring
Magnet’ rotor design and Neodymium
magnet material to deliver premium
torque output at a lower cost. Both
motors have 2500 pulse/rev integrated
encoder feedback for high-precision
positioning.”
The Dyesol team programmed the
machine and chose to make it a selfcontained, stand-alone unit. They
downloaded the operating routines to
the NextMove e100 controller, although
it is capable of interfacing to an external
PC if that suits the application. They
also developed an interface with a Baldor
12-inch color touch-screen HMI panel
mounted on the machine.
with a Baldor HMI touch-screen
control panel, operational software
developed by Dyesol, based on the
inbuilt Baldor Mint software, 2 x 3
amp Baldor MicroFlex servo drives
and two Baldor BSM brushless servo
motors. “The NextMove e100 is very
powerful and capable of controlling up
to 16 interpolated axes, yet is still cost
effective for our 2 axis application. We
also like the MicroFlex e100 Ethernetbased servo drives because now we
can connect all of the limit and home
position switches back to the MicroFlex
servo drives,” explains Oh.
®
12 | Solutions Magazine | Number 6
Baldor’s Mint Motion Language
is a high-speed compiled BASIC
programming language for motion
and machine control that combines
multitasking capability for motion,
I/O, HMI and communication tasks,
allowing complex applications to be
divided into simpler, more manageable
sub-tasks.
Mint WorkBench is a Windows tool
that is common across Baldor’s range
of NextMove motion controllers,
servo drives and high-performance
inverter and vector drives. It offers an
®
“Baldor offers us a good
development platform, a
neat package with proven
compatibility between
components, robust
design and worldwide
availability and support.”
Anthony Oh,
senior design engineer,
Dyesol
easy-to-use development front end
for Mint programming, with its color
highlighting of keywords and contextsensitive help. The program navigator
makes it a breeze to navigate the source
code, no matter how complicated.
“The interface we developed is simple
yet complete,” explains Oh. “It allows
the machine to be operated by relatively
unskilled personnel after just a small
amount of training. All of the necessary
adjustments to allow for different
shapes and sizes of DSCs are easily
made and selected on the HMI screen,
and operation is fully automatic and
self-managed after the start command.”
Baldor 80C-175AF brushless servo motor with integrated encoder feedback for precise Y-axis drive.
After calculating the machine’s
requirements, Baldor engineers assisted
Dyesol engineers in the selection of
motors. A very compact R-series motor
was chosen for the X-axis. Baldor
Systems Engineer Jason DeSouza says
with a body size of just 40mm diameter
and 59mm length, the Baldor motor
is an elegant solution. “These motors
provide a high torque to inertia ratio
“The fact that Baldor supplies the
necessary software to enable us to
develop our programs and our own
interface free of charge is another
reason we chose them as our preferred
supplier,” states Oh. “Often, licensing
fees can add considerably to the initial
costs, and ongoing upgrades can also
add to the cost of ownership.”
The managing director of Baldor
Australia, Daniel Vera, believes
Dyesol DSC technology is making
a real difference in the development
of sustainable and renewable energy
and is pleased to be involved with an
Australian company producing such
cutting-edge technology.
“We appreciate how important R&D
is in the field of energy production
and usage, and as pressure mounts on
the world’s resources over the coming
years, technology from companies like
Baldor and Dyesol will continue to
enhance the world’s efforts in reducing
fossil fuel dependence.”
The Dyesol Dye Profiling Machine with fluid containers and pumps mounted underneath.
Baldor 12-inch touch-screen HMI panel.
Number 6 | Solutions Magazine | 13
F e at u r e s
F e at u r e s
and high acceleration capabilities in an
ultra-compact body format,” explains
DeSouza. “For the Y-axis, a more
powerful motor was required because
it’s mounted under the table and
incorporates a cogged belt drive to the
spindle. The unit came from our range
of C-series motors, which use our ‘Ring
Magnet’ rotor design and Neodymium
magnet material to deliver premium
torque output at a lower cost. Both
motors have 2500 pulse/rev integrated
encoder feedback for high-precision
positioning.”
The Dyesol team programmed the
machine and chose to make it a selfcontained, stand-alone unit. They
downloaded the operating routines to
the NextMove e100 controller, although
it is capable of interfacing to an external
PC if that suits the application. They
also developed an interface with a Baldor
12-inch color touch-screen HMI panel
mounted on the machine.
with a Baldor HMI touch-screen
control panel, operational software
developed by Dyesol, based on the
inbuilt Baldor Mint software, 2 x 3
amp Baldor MicroFlex servo drives
and two Baldor BSM brushless servo
motors. “The NextMove e100 is very
powerful and capable of controlling up
to 16 interpolated axes, yet is still cost
effective for our 2 axis application. We
also like the MicroFlex e100 Ethernetbased servo drives because now we
can connect all of the limit and home
position switches back to the MicroFlex
servo drives,” explains Oh.
®
12 | Solutions Magazine | Number 6
Baldor’s Mint Motion Language
is a high-speed compiled BASIC
programming language for motion
and machine control that combines
multitasking capability for motion,
I/O, HMI and communication tasks,
allowing complex applications to be
divided into simpler, more manageable
sub-tasks.
Mint WorkBench is a Windows tool
that is common across Baldor’s range
of NextMove motion controllers,
servo drives and high-performance
inverter and vector drives. It offers an
®
“Baldor offers us a good
development platform, a
neat package with proven
compatibility between
components, robust
design and worldwide
availability and support.”
Anthony Oh,
senior design engineer,
Dyesol
easy-to-use development front end
for Mint programming, with its color
highlighting of keywords and contextsensitive help. The program navigator
makes it a breeze to navigate the source
code, no matter how complicated.
“The interface we developed is simple
yet complete,” explains Oh. “It allows
the machine to be operated by relatively
unskilled personnel after just a small
amount of training. All of the necessary
adjustments to allow for different
shapes and sizes of DSCs are easily
made and selected on the HMI screen,
and operation is fully automatic and
self-managed after the start command.”
Baldor 80C-175AF brushless servo motor with integrated encoder feedback for precise Y-axis drive.
After calculating the machine’s
requirements, Baldor engineers assisted
Dyesol engineers in the selection of
motors. A very compact R-series motor
was chosen for the X-axis. Baldor
Systems Engineer Jason DeSouza says
with a body size of just 40mm diameter
and 59mm length, the Baldor motor
is an elegant solution. “These motors
provide a high torque to inertia ratio
“The fact that Baldor supplies the
necessary software to enable us to
develop our programs and our own
interface free of charge is another
reason we chose them as our preferred
supplier,” states Oh. “Often, licensing
fees can add considerably to the initial
costs, and ongoing upgrades can also
add to the cost of ownership.”
The managing director of Baldor
Australia, Daniel Vera, believes
Dyesol DSC technology is making
a real difference in the development
of sustainable and renewable energy
and is pleased to be involved with an
Australian company producing such
cutting-edge technology.
“We appreciate how important R&D
is in the field of energy production
and usage, and as pressure mounts on
the world’s resources over the coming
years, technology from companies like
Baldor and Dyesol will continue to
enhance the world’s efforts in reducing
fossil fuel dependence.”
The Dyesol Dye Profiling Machine with fluid containers and pumps mounted underneath.
Baldor 12-inch touch-screen HMI panel.
Number 6 | Solutions Magazine | 13
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
F e at u r e s
F e at u r e s
Leads to Success
in the Iron Range
When Aggregate Systems got the
job to build more than 55 custom
conveyors for a new iron-making plant
in Minnesota, there was no question
who they would choose to partner with
on the project and no question about
the products they would use. Since
the family-owned business opened
its doors in 1996, they have worked
with distributor Transmission & Fluid
Equipment (TFE) and standardized on
Baldor•Dodge and Baldor•Reliance
products. With a strong history of
support and product performance,
Aggregate Systems was confident it had
the right team to take on a project of
this size and make it a success.
®
A Trusted
Partnership
nuggets produced will be shipped by
rail to SDI’s three Indiana steel mills.
While building the material handling
equipment to convey resources from
one area to the next was a big project
with some sizeable conveyors, Sibert
®
Based in Rome City, Indiana, Aggregate
Systems specializes in fabricating
custom material handling systems
for the aggregate, asphalt and ready
mix industries. Tim Sibert, Aggregate
Systems project manager, says from the
beginning, the company’s strategy was
to build a solid reputation by providing
superior quality to its customers.
“When my dad started this company,
he decided from day one that we would
use Baldor products,” says Sibert. “The
Baldor•Reliance and Baldor•Dodge
brand names are big in this industry;
they stand for quality, and that’s what we
have always used. We also chose to work
exclusively with TFE, a strong Baldor
distributor; they know exactly how to
support us, and we have never had any
reason to change.”
The custom conveyors for the Mesabi
Nugget project would take Aggregate
Systems to Hoyt Lakes, on the Mesabi
Iron Range in the wilds of Northeastern
Minnesota. Co-investors Steel
Dynamics, Inc. (SDI) and Kobe Steel,
Ltd., were building the first plant in the
world to commercially produce iron
nuggets using the revolutionary ITmk3
®
22 | Solutions Magazine | Number 5
process, which stands for “iron-making
technology mark three.” Developed by
Kobe Steel, the groundbreaking iron
making technology uses a rotary hearth
furnace to turn iron ore, pulverized coal
and limestone into iron nuggets that
have 97% iron content. Most of the
Groundbreaking iron-making technology uses a rotary hearth furnace to turn iron ore, pulverized coal
and limestone into iron nuggets that have 97% iron content. Most of the nuggets produced at the Mesabi
Nugget plant are shipped by rail to three Indiana steel mills owned by Steel Dynamics, Inc.
Number 6 | Solutions Magazine | 23
F e at u r e s
F e at u r e s
Leads to Success
in the Iron Range
When Aggregate Systems got the
job to build more than 55 custom
conveyors for a new iron-making plant
in Minnesota, there was no question
who they would choose to partner with
on the project and no question about
the products they would use. Since
the family-owned business opened
its doors in 1996, they have worked
with distributor Transmission & Fluid
Equipment (TFE) and standardized on
Baldor•Dodge and Baldor•Reliance
products. With a strong history of
support and product performance,
Aggregate Systems was confident it had
the right team to take on a project of
this size and make it a success.
®
A Trusted
Partnership
nuggets produced will be shipped by
rail to SDI’s three Indiana steel mills.
While building the material handling
equipment to convey resources from
one area to the next was a big project
with some sizeable conveyors, Sibert
®
Based in Rome City, Indiana, Aggregate
Systems specializes in fabricating
custom material handling systems
for the aggregate, asphalt and ready
mix industries. Tim Sibert, Aggregate
Systems project manager, says from the
beginning, the company’s strategy was
to build a solid reputation by providing
superior quality to its customers.
“When my dad started this company,
he decided from day one that we would
use Baldor products,” says Sibert. “The
Baldor•Reliance and Baldor•Dodge
brand names are big in this industry;
they stand for quality, and that’s what we
have always used. We also chose to work
exclusively with TFE, a strong Baldor
distributor; they know exactly how to
support us, and we have never had any
reason to change.”
The custom conveyors for the Mesabi
Nugget project would take Aggregate
Systems to Hoyt Lakes, on the Mesabi
Iron Range in the wilds of Northeastern
Minnesota. Co-investors Steel
Dynamics, Inc. (SDI) and Kobe Steel,
Ltd., were building the first plant in the
world to commercially produce iron
nuggets using the revolutionary ITmk3
®
22 | Solutions Magazine | Number 5
process, which stands for “iron-making
technology mark three.” Developed by
Kobe Steel, the groundbreaking iron
making technology uses a rotary hearth
furnace to turn iron ore, pulverized coal
and limestone into iron nuggets that
have 97% iron content. Most of the
Groundbreaking iron-making technology uses a rotary hearth furnace to turn iron ore, pulverized coal
and limestone into iron nuggets that have 97% iron content. Most of the nuggets produced at the Mesabi
Nugget plant are shipped by rail to three Indiana steel mills owned by Steel Dynamics, Inc.
Number 6 | Solutions Magazine | 23
F e at u r e s
F e at u r e s
says his team focused on doing what
they’ve always done with the products
they have always used.
“The Baldor•Dodge TXT and the
Torque-Arm II reducers are the
standard in this industry,” says Sibert.
“Then we match them up with
Baldor•Reliance motors, Baldor•Dodge
Mine Duty Extra pulleys, USAF and
ISAF bearings. These are rugged
products that have a proven history of
success in this industry.”
™
Knowing exactly what products to
use on the project, the next step was
getting TFE involved to get the process
started.
Turning to Another
Trusted Partner
Like Aggregate Systems, TFE is also
a family-owned and operated business
that is very loyal to Baldor and all
its products. Headquartered in Fort
Wayne, Indiana, TFE has been a Baldor
distributor since its doors opened in
1964. Chris Hughes, TFE president
and co-owner, says quality is the reason
Baldor products are their leading line.
“It’s not only about the quality of
the products, it’s also the quality of
the support we receive from Baldor,”
says Hughes. “From corporate, to the
plants, to the local Baldor•Dodge sales
engineer calling on us, Baldor makes us
feel like we are doing business together
as one team, and that works really well
for us.”
TFE has had an equally strong
partnership with Aggregate Systems
for the past 14 years, and the company
trusts TFE to do the right thing.
“That’s why, when they told us about
the Mesabi Nugget project and the
number of conveyors they were going
to build, we immediately thought this
would be an ideal project to quote
through Baldor’s System-1 group,”
explains Miller. “We realized that
by coordinating the project through
™
A size 10 Baldor•Dodge TXT, Baldor•Dodge V-belt drive and 75 HP Baldor•Reliance motor were selected to power one of the largest conveyors at the Mesabi
Nugget plant. (Please note that this equipment was not running, and the guards were removed for photographic purposes.)
24 | Solutions Magazine | Number 6
When Aggregate Systems got the job to build more than 55 customer conveyors for the Mesabi
Nugget plant, it chose to partner with distributor Transmission & Fluid Equipment and standardize on
Baldor•Reliance and Baldor•Dodge products.
Number 6 | Solutions Magazine | 25
F e at u r e s
F e at u r e s
says his team focused on doing what
they’ve always done with the products
they have always used.
“The Baldor•Dodge TXT and the
Torque-Arm II reducers are the
standard in this industry,” says Sibert.
“Then we match them up with
Baldor•Reliance motors, Baldor•Dodge
Mine Duty Extra pulleys, USAF and
ISAF bearings. These are rugged
products that have a proven history of
success in this industry.”
™
Knowing exactly what products to
use on the project, the next step was
getting TFE involved to get the process
started.
Turning to Another
Trusted Partner
Like Aggregate Systems, TFE is also
a family-owned and operated business
that is very loyal to Baldor and all
its products. Headquartered in Fort
Wayne, Indiana, TFE has been a Baldor
distributor since its doors opened in
1964. Chris Hughes, TFE president
and co-owner, says quality is the reason
Baldor products are their leading line.
“It’s not only about the quality of
the products, it’s also the quality of
the support we receive from Baldor,”
says Hughes. “From corporate, to the
plants, to the local Baldor•Dodge sales
engineer calling on us, Baldor makes us
feel like we are doing business together
as one team, and that works really well
for us.”
TFE has had an equally strong
partnership with Aggregate Systems
for the past 14 years, and the company
trusts TFE to do the right thing.
“That’s why, when they told us about
the Mesabi Nugget project and the
number of conveyors they were going
to build, we immediately thought this
would be an ideal project to quote
through Baldor’s System-1 group,”
explains Miller. “We realized that
by coordinating the project through
™
A size 10 Baldor•Dodge TXT, Baldor•Dodge V-belt drive and 75 HP Baldor•Reliance motor were selected to power one of the largest conveyors at the Mesabi
Nugget plant. (Please note that this equipment was not running, and the guards were removed for photographic purposes.)
24 | Solutions Magazine | Number 6
When Aggregate Systems got the job to build more than 55 customer conveyors for the Mesabi
Nugget plant, it chose to partner with distributor Transmission & Fluid Equipment and standardize on
Baldor•Reliance and Baldor•Dodge products.
Number 6 | Solutions Magazine | 25
F e at u r e s
F e at u r e s
System-1, we could relieve Aggregate
Systems of a lot of the logistics details,
plus help them with their installation
and labor costs.”
Another way TFE simplified the
process for Aggregate Systems was
to have all the Baldor packages and
other equipment shipped to its large
warehouse. According to Jay Millard,
TFE sales manager, since TFE is
accustomed to receiving and shipping
equipment, it made more sense for them
to handle this part of the job.
“When my dad
started this company,
he decided from day
one that we would use
Baldor products. The
Baldor•Reliance and
Baldor•Dodge brand
names are big in this
industry; they stand for
quality.”
“When the equipment came in, we
sorted it by conveyor, labeled it, put
it on a pallet and shipped it to either
Rome City or Minnesota,” explains
Millard. “We worked closely with
Aggregate Systems to figure out which
conveyors needed to be done first, and
we worked the project that way, sending
them what they needed, when they
needed it. It worked because we have a
close relationship with both Aggregate
Systems and Baldor, and we have open
communications with both companies.”
For his part, Sibert says the partnership
he has with TFE and Baldor is strong.
He welcomes the extra support from
both and has complete trust that both
Tim Sibert,
project manager,
Aggregate Systems
companies will work in his best interest.
Sibert calls the Mesabi Nugget project
a huge success, but then again, that’s
exactly what he expected with the team
he had working with him.
“We choose to partner with Baldor and
TFE because not only can I trust them
while we are working on the job, I also
know that both will stand behind the
project when it’s done,” says Sibert.
“Our company is in it for the long haul,
and we live on our reputation. That’s
why we only work with others that
we can count on, and we only choose
products that are dependable. That’s
why we choose to partner with Baldor
and TFE.”
Baldor’s System-1 group provides
expertise in design and product
selection, as well as quoting and
ordering multiple products in one
complete package. This was not the first
time TFE had worked with System-1,
but it was the first time they had worked
together on a project of this size.
“Aggregate Systems would give us all the
details, like tons per hour, belt width,
belt length and so on,” explains Miller.
“Then we worked directly with System1 to help us do the engineering work,
and then finally to help with selecting
the correct products. We look at
System-1 as sort of our own engineering
firm, plus we get one part number and
one invoice. It’s all so easy.”
26 | Solutions Magazine | Number 6
Aggregate Systems chose to use Baldor•Dodge USAF (pictured here) and ISAF bearings throughout
the project. Company leaders describe these products as rugged with a proven history of success in the
industry.
Distributor Transmission & Fluid Equipment (TFE) chose to work with Baldor’s System-1 group on the large project. TFE worked directly with System-1 for
help with the engineering work and selection of the correct products. According to the TFE sales team, they look at System-1 as sort of their own engineering
firm, plus they like the fact that they get one part number and one invoice for the job.
Number 6 | Solutions Magazine | 27
F e at u r e s
F e at u r e s
System-1, we could relieve Aggregate
Systems of a lot of the logistics details,
plus help them with their installation
and labor costs.”
Another way TFE simplified the
process for Aggregate Systems was
to have all the Baldor packages and
other equipment shipped to its large
warehouse. According to Jay Millard,
TFE sales manager, since TFE is
accustomed to receiving and shipping
equipment, it made more sense for them
to handle this part of the job.
“When my dad
started this company,
he decided from day
one that we would use
Baldor products. The
Baldor•Reliance and
Baldor•Dodge brand
names are big in this
industry; they stand for
quality.”
“When the equipment came in, we
sorted it by conveyor, labeled it, put
it on a pallet and shipped it to either
Rome City or Minnesota,” explains
Millard. “We worked closely with
Aggregate Systems to figure out which
conveyors needed to be done first, and
we worked the project that way, sending
them what they needed, when they
needed it. It worked because we have a
close relationship with both Aggregate
Systems and Baldor, and we have open
communications with both companies.”
For his part, Sibert says the partnership
he has with TFE and Baldor is strong.
He welcomes the extra support from
both and has complete trust that both
Tim Sibert,
project manager,
Aggregate Systems
companies will work in his best interest.
Sibert calls the Mesabi Nugget project
a huge success, but then again, that’s
exactly what he expected with the team
he had working with him.
“We choose to partner with Baldor and
TFE because not only can I trust them
while we are working on the job, I also
know that both will stand behind the
project when it’s done,” says Sibert.
“Our company is in it for the long haul,
and we live on our reputation. That’s
why we only work with others that
we can count on, and we only choose
products that are dependable. That’s
why we choose to partner with Baldor
and TFE.”
Baldor’s System-1 group provides
expertise in design and product
selection, as well as quoting and
ordering multiple products in one
complete package. This was not the first
time TFE had worked with System-1,
but it was the first time they had worked
together on a project of this size.
“Aggregate Systems would give us all the
details, like tons per hour, belt width,
belt length and so on,” explains Miller.
“Then we worked directly with System1 to help us do the engineering work,
and then finally to help with selecting
the correct products. We look at
System-1 as sort of our own engineering
firm, plus we get one part number and
one invoice. It’s all so easy.”
26 | Solutions Magazine | Number 6
Aggregate Systems chose to use Baldor•Dodge USAF (pictured here) and ISAF bearings throughout
the project. Company leaders describe these products as rugged with a proven history of success in the
industry.
Distributor Transmission & Fluid Equipment (TFE) chose to work with Baldor’s System-1 group on the large project. TFE worked directly with System-1 for
help with the engineering work and selection of the correct products. According to the TFE sales team, they look at System-1 as sort of their own engineering
firm, plus they like the fact that they get one part number and one invoice for the job.
Number 6 | Solutions Magazine | 27
F e at u r e s
New Road-Going Trommel
Uses Baldor•Dodge® Bearings
to Simplify On-Site Maintenance
Stelex Construction Equipment,
manufacturer of the renowned Hercules
range of trommels, has standardized
on Baldor•Dodge Imperial ISN
mounted spherical roller bearings
for its new HT182M road-going
trommel. Launched at Hillhead 2010,
the HT182M is already generating
a very high level of interest in the
quarrying industry. In fact, Stelex sold
two machines during the course of the
event, to customers from Australia and
the USA.
Stelex Construction Equipment, manufacturer of the renowned Hercules range of trommels, has
standardized on Baldor•Dodge Imperial ISN bearings for all the main rotational load-bearing parts on its
new HT182M road-going trommel.
uninstalled in less than 15 minutes.
What’s more, the bearings can be fitted
without specialist tools and are supplied
pre-lubricated and fully sealed, making
them perfect for on-site maintenance
purposes. Not that they need replacing
very often – we are getting in excess
of 10,000 hours of service, which is a
very good figure, especially given the
aggressive operating environment. We
currently use 90 mm Imperial ISN
bearings – there are eight of these on
the HT182M, which are contained in
ISN pillow blocks – but we are also
looking at using the 140 mm models on
larger trommels in development.”
The company chose to standardize on the Baldor•Dodge Imperial ISN bearing because it’s easy to
install and easy to maintain.
on Dodge Imperial ISN bearings for
all of the machine’s main rotational
load-bearing parts. These bearings
use a patented thin-wall push-pull
adapter system, which can be either
metric or standard inch sizes, and
achieves clearance setting without
the use of feeler gauges. The bearing
28 | Solutions Magazine | Number 6
2010 Compliant Since 1983
Since our beginning in 1920, Baldor
has led the industry in developing
industrial electric motors that
deliver greater performance and
reliability while using less electricity.
That commitment continued in
1983 with the introduction of
our Super-E line of motors. In
horsepower ratings from fractional
to 15,000, Baldor offers the
broadest choice of energy efficient
motors available in the world.
™
One of the major features of the new
stone cleaning and sizing machine
is deployment flexibility, thanks to
the design’s incorporation of a low
loader trailer. Aside from deployment
flexibility, one of Stelex’s key design
parameters for the new trommel was
ease of on-site maintenance. The
company therefore chose to standardize
Super-E Motors
®
can be installed or uninstalled simply
by turning a locknut clockwise or
counterclockwise.
According to Stelex’s managing director,
Richard Evans, “Every Baldor•Dodge
Imperial ISN bearing does what it says
on the box – it can be installed and
The HT182M road-going trommel
is the ideal solution for cleaning and
sizing quarried stone, regardless of
location. The machine’s integrated low
loader trailer enables it to be driven
to the exact point of need on-site. It is
capable of handling blasted, ripped or
as-dug material, and can process up to
500 tons per hour. Typical applications
include quarry overburden cleanup and
the removal of fines prior to crushing.
Every Super-E motor is designed
and built to meet or exceed the
efficiency levels defined by NEMA
in the USA, NRC in Canada and IEC
60034-30 IE3 in Europe.
Many years ago, Baldor
Super-E motors were
recognized by the
Consortium for Energy
Baldor will help you get ready for
December 2010 today because
we’ve been ready since 1983.
Efficiency as the first
premium efficiency motor
line to meet their stringent
criteria. And, every Super-E
motor meets the compliance
standards for the Energy
Independence and
Security Act of 2007,
which takes effect in
December 2010.
Are You
2010 Ready?
Quality Is in the Details
Super-E premium efficient motors
represent quality to the highest
degree. Look inside a Super-E and
you’ll find premium-grade copper
windings, annealed laminations
of superior-grade steel, premium
bearings and low-loss fans,
enabling Baldor’s Super-E motors
to run cooler, quieter and longer
with better reliability than any other
industrial motor.
®
2010 Baldor Electric Company
When you choose
Baldor’s Super-E motors,
you’re ready and compliant
immediately. For any design or
application, there’s a Super-E to
meet even the most demanding
applications. Log on today and
receive your free copy of the
Energy Independence and Security
Act of 2007 document, our Method
to Reduce Energy Costs case study,
our award-winning BE$T Baldor
Energy Savings Tool CD and our
Super-E product line brochure.
baldor.com
The Energy Independence and
Security Act of 2007 will take effect
December 19, 2010. Because
electric motors consume more
than 63% of electricity used by U.S.
industry, the act addressed new
energy savings regulations that will
directly affect the electric motors
you use in your facilities, as well
as motors used in new equipment
design. Log on today to baldor.com
for additional information.
F e at u r e s
New Road-Going Trommel
Uses Baldor•Dodge® Bearings
to Simplify On-Site Maintenance
Stelex Construction Equipment,
manufacturer of the renowned Hercules
range of trommels, has standardized
on Baldor•Dodge Imperial ISN
mounted spherical roller bearings
for its new HT182M road-going
trommel. Launched at Hillhead 2010,
the HT182M is already generating
a very high level of interest in the
quarrying industry. In fact, Stelex sold
two machines during the course of the
event, to customers from Australia and
the USA.
Stelex Construction Equipment, manufacturer of the renowned Hercules range of trommels, has
standardized on Baldor•Dodge Imperial ISN bearings for all the main rotational load-bearing parts on its
new HT182M road-going trommel.
uninstalled in less than 15 minutes.
What’s more, the bearings can be fitted
without specialist tools and are supplied
pre-lubricated and fully sealed, making
them perfect for on-site maintenance
purposes. Not that they need replacing
very often – we are getting in excess
of 10,000 hours of service, which is a
very good figure, especially given the
aggressive operating environment. We
currently use 90 mm Imperial ISN
bearings – there are eight of these on
the HT182M, which are contained in
ISN pillow blocks – but we are also
looking at using the 140 mm models on
larger trommels in development.”
The company chose to standardize on the Baldor•Dodge Imperial ISN bearing because it’s easy to
install and easy to maintain.
on Dodge Imperial ISN bearings for
all of the machine’s main rotational
load-bearing parts. These bearings
use a patented thin-wall push-pull
adapter system, which can be either
metric or standard inch sizes, and
achieves clearance setting without
the use of feeler gauges. The bearing
28 | Solutions Magazine | Number 6
2010 Compliant Since 1983
Since our beginning in 1920, Baldor
has led the industry in developing
industrial electric motors that
deliver greater performance and
reliability while using less electricity.
That commitment continued in
1983 with the introduction of
our Super-E line of motors. In
horsepower ratings from fractional
to 15,000, Baldor offers the
broadest choice of energy efficient
motors available in the world.
™
One of the major features of the new
stone cleaning and sizing machine
is deployment flexibility, thanks to
the design’s incorporation of a low
loader trailer. Aside from deployment
flexibility, one of Stelex’s key design
parameters for the new trommel was
ease of on-site maintenance. The
company therefore chose to standardize
Super-E Motors
®
can be installed or uninstalled simply
by turning a locknut clockwise or
counterclockwise.
According to Stelex’s managing director,
Richard Evans, “Every Baldor•Dodge
Imperial ISN bearing does what it says
on the box – it can be installed and
The HT182M road-going trommel
is the ideal solution for cleaning and
sizing quarried stone, regardless of
location. The machine’s integrated low
loader trailer enables it to be driven
to the exact point of need on-site. It is
capable of handling blasted, ripped or
as-dug material, and can process up to
500 tons per hour. Typical applications
include quarry overburden cleanup and
the removal of fines prior to crushing.
Every Super-E motor is designed
and built to meet or exceed the
efficiency levels defined by NEMA
in the USA, NRC in Canada and IEC
60034-30 IE3 in Europe.
Many years ago, Baldor
Super-E motors were
recognized by the
Consortium for Energy
Baldor will help you get ready for
December 2010 today because
we’ve been ready since 1983.
Efficiency as the first
premium efficiency motor
line to meet their stringent
criteria. And, every Super-E
motor meets the compliance
standards for the Energy
Independence and
Security Act of 2007,
which takes effect in
December 2010.
Are You
2010 Ready?
Quality Is in the Details
Super-E premium efficient motors
represent quality to the highest
degree. Look inside a Super-E and
you’ll find premium-grade copper
windings, annealed laminations
of superior-grade steel, premium
bearings and low-loss fans,
enabling Baldor’s Super-E motors
to run cooler, quieter and longer
with better reliability than any other
industrial motor.
®
2010 Baldor Electric Company
When you choose
Baldor’s Super-E motors,
you’re ready and compliant
immediately. For any design or
application, there’s a Super-E to
meet even the most demanding
applications. Log on today and
receive your free copy of the
Energy Independence and Security
Act of 2007 document, our Method
to Reduce Energy Costs case study,
our award-winning BE$T Baldor
Energy Savings Tool CD and our
Super-E product line brochure.
baldor.com
The Energy Independence and
Security Act of 2007 will take effect
December 19, 2010. Because
electric motors consume more
than 63% of electricity used by U.S.
industry, the act addressed new
energy savings regulations that will
directly affect the electric motors
you use in your facilities, as well
as motors used in new equipment
design. Log on today to baldor.com
for additional information.
solutions
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Permit No. 175
A Publication Featuring Baldor Electric Company Products
Number 6
magazine
Built
to Last...
Albert Frei & Sons
Choose Baldor Products
for Crushing Plant
Expansion
World Headquarters
P.O. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1) 479.646.4711, Fax: (1) 479.648.5792, International Fax: (1) 479.648.5895
baldor.com
©2010 Baldor Electric Company
Solutions1010
All Rights Reserved. Printed in USA.
10/10-AG-13M
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