Working Together to Make Conveyors Green
Energy Savings That Makes
Dollars & Sense
Session Overview
This Webinar is targets attendees with leadership and management
responsibilities for Operations, Logistics and Distribution.
In this session, Rick DeFiesta, Senior Account Executive – Solutions
Integration, of Wynright, will discuss the latest Motor Driven Roller
Technologies and the role it plays in the future of Green Conveyor
Systems. Rick will share his insights on why customers are demanding
change, what are the key components and the advantages you can
expect to gain using a Green Conveyor System
About the Presenter: Rick DeFiesta
Rick has over thirty years in automated material handling on both the vendor
and user side of the industry. Rick is part of the Wynright solutions team and is
based out of Atlanta, Georgia. Prior to joining Wynright, Rick worked at the
world’s largest 3PL in cold storage where he implemented their first ASRS
automated warehouse in the US. The design included energy management and
regeneration through software and controls.
In the past Rick participated as a guest speaker at the Georgia Tech Logistics
Institute on the topic of automated order fulfillment.
Allen-Bradley® Components
From Rockwell Automation
Traditional Conveyor Drive Characteristics
• Driven by Belts, Chains, or Shafts
• Powered by Motors / Reducers
• Chains / Sprockets / Bearings
• Terminal Ends
Motor Driven Roller Technology
•
•
•
•
•
A 24v motor is located within the roller
Each MDR Roller plugs into a power / communications card
The MDR roller, along with slaved rollers, act as a controlled ‘zone’
Single motor zone lengths of up to 30”
No Greasing or Lubing Needed
MDR Conveyor Drive Characteristics
• Driven by 24V Motors
• 480V or 110V Power Supplies
• 24 MDR rollers per 480V Power
Supply
• 12 MDR rollers per 110V Power
Supply
• Slaved rollers used to create zones
Always On versus Run-On-Demand
Traditional Conveyor
•
•
•
•
1 controlled zone of power
Product entering a control zone, the control zone is powered
Product exiting a control zone, the control zone IS powered
Accumulated product in a control zone, the control zone IS powered
MDR Conveyor
•
•
•
•
5 controlled zones of power
Product entering a control zone, the control zone is powered
Product exiting a control zone, the control zone is NOT powered
Accumulated product in a control zone, the control zone is NOT powered
Where to use MDR Conveyor
• In areas where DC personnel are in close proximity to
the conveyor
• In areas where noise levels are a concern
• When multiple directional changes are required
• In areas where conveyor is densely packed or has
repeating footprints
Cost Justification
Packing System – Running 2 Shifts (16 hrs / day)
MDR Conveyor
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•
•
•
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•
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600’-0” of MDR Driven Conveyor
300 Controlled Accumulation Zones
6 MDR Driven Curves
12 480V Power Supplies
0 Air Actuated Brakes
Conveyor Speed is 100 FPM
6 Carton Seal Lines at 15 CPM
Traditional Conveyor
•
•
•
•
•
•
•
600’-0” of Belt Driven Conveyor
300 Accumulation Zones
6 Slaved V-Belt Driven Curves
12 460V Motors
12 Air Actuated Brakes
Conveyor Speed is 100 FPM
6 Carton Seal Lines at 15 CPM
12% Up Front Initial Investment
Packing System – Running 2 Shifts (16 hrs / day)
MDR Conveyor
Traditional Conveyor
System Turn-Key Price:
System Turn-Key Price:
$315,000
$280,000
Difference:
$35,000
12.5% Up Front Initial Investment
Energy Usage Calculations
Packing System – Running 2 Shifts (16 hrs / day)
System Parameters for Horse Power and Run Rate Calculation
Conveyor Length:
Zone Length:
Conveyor Speed:
Carton Rate:
Live Load:
Precision Bearings:
Utility Location:
Total Weight of Load:
Roller Run Time:
Roller Run Rate (RRR):
Cost per kWhr:
600
24
100
15
20
Y
Anywhere, USA
feet
inches
ft / min
carton / min
lbs / ft
Y/N
40
1.2
18
0.1320
lbs
sec / carton
sec / min
$ / kWhr
Each motorized roller runs 18.00 seconds (RRR) out of each minute to achieve a 15 CPM Rate!
Energy Usage Calculations (16 hours per day)
Traditional Conveyor Packing System
Continuous Running Conveyor Parameters
3 Phase Voltage:
460
V AC
Single Motor FLA:
3.1
Amperes
Motor Power Factor:
Motor Efficiency:
Motor Count:
77
82.5
12
%
%
Total Amperage:
37.2
Total Kilowatts:
22.8212
Motor Specifications
460V AC
HP Power Factor
0.5
63.0%
0.75
60.0%
230V AC
Efficiency
FLA
1
1.5
FLA
2
3
74.0%
75.5%
1
71.0%
1.7
3.4
78.5%
1.5
72.0%
2.5
5
78.5%
kW
2
77.0%
3.1
6.2
82.5%
Amperes
Total Energy:
3.73
kWhr
3
82.0%
4.1
8.2
84.0%
Total Energy w/ Efficiency
4.52
kWhr
5
80.0%
6.6
13.2
85.5%
7.5
77.0%
10.4
20.8
87.5%
Calculated Total HP:
Effective Belt Pull:
Effective HP:
5
HP
1190
lbs
3.8
HP
One Shift (8 hrs / day)
Two Shifts (16 hrs / day)
Cost Per Month:
$ 733
$ 1,466
Cost Per Year:
$ 8,800
$ 17,500
Energy Usage Calculations (16 hours per day)
MDR Conveyor Packing System
Motorized Roller Conveyor Parameters
Drive Roller Voltage:
Single Roller Current Draw:
24
V DC
0.75
Current Draw - Weight and Speed Chart
Amperes
Weight < 45 lbs
Weight 55 - 64 lbs
Speed (FPM)
Amps
Speed (FPM)
Amps
< 100
0.75
< 100
1.3
Roller Speed:
100
ft / min
Total Weight of Load:
40
lbs
101 - 150
1.1
101 - 150
1.5
Single Roller Wattage:
18
Watts
150 - 200
1.5
150 - 200
1.75
0.0054
kWhr
Total Energy Used:
1.62
kWhr
Total Drive Roller Count:
300
Single Roller Energy:
Weight < 45 lbs
Weight 55 - 64 lbs
Speed (FPM)
Amps
Speed (FPM)
Amps
< 100
1.1
< 100
1.5
101 - 150
1.3
101 - 150
1.75
150 - 200
1.5
150 - 200
1.9
One Shift (8 hrs / day)
Two Shifts (16 hrs / day)
Cost Per Month:
$
52
$
104
Cost Per Year:
$
625
$
1,250
Energy Savings
Packing System – Running 2 Shifts (16 hrs / day)
Cost Per Month:
Cost Per Year:
MDR System
Traditional System
$ 104
$ 1,248
$ 1,466
$ 17,592
Savings Per Month:
Savings Per Year:
$1,362
$16,344
Cents per Kilowatt hour
Rise in Cost of Energy over the last decade
% Rate Increase From 2004 to 2008
•
Data provided by the Official Nebraska Government Website – www.neo.ne.gov
10 year Total Cost of Ownership (Less Maintenance)
MDR System
Traditional System
System Turnkey Price
$315,000
$280,000
10 Year Energy Cost (16 hours per day)
$12,480
$175,920
Total
$327,480
$455,920
Savings After 10 Years - $128,440
*Assuming system rate running at 15 CPM and energy cost is $0.1320 / kWhr.
ROI is approximately 33 Months to cover $35,000 CAPEX premium.
Traditional Conveyor Maintenance
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•
•
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Lube Drive Chains
Check Belt Tracking / Re-Lace Belting
Grease Bearings in TE’s & Drives
Change Oil in Reducers
Monitor Drives
Tension Drive Chain
MDR Conveyor Maintenance
• Occasionally replace faulty rollers
• Occasionally replace faulty cards
• Check Power Supplies
Traditional Conveyor Guarding & Safety
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•
•
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Drive Belts
Chains and Sprocket
Exposed Terminal Ends
Roller pinch points
E-Stops in Associate Accessible Areas
MDR Conveyor Guarding & Safety
• Don’t trip over it while you marvel at how quiet it operates.
Other Competitive Advantages
Cost of Integration:
•
Reduced Field Wiring Install Time and Materials
Feature Rich Design:
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•
•
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•
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Non-Contact Accumulation
Green Product Line: Low Energy Consumption
Singulation or Slug Release Modes
Intuitive LED Status Indicators
Belted MDR Handle smaller, lighter or irregular shaped product
• Can be used to accumulate or gap product on inclines and declines
Safe, Reliable and Quiet Operation
Application Examples - Case sealer operation
Application Examples - Audit and pack work station
Application Examples - 20 cpm pick zone sort modules
Application Examples - MDR double-wide gate
Application Examples – Value-add work stations
Application Examples - Take-away from sorter
Application Examples - Accumulation
Application Examples – Accumulation on an Incline
Questions?