Energy Savings That Makes Dollars

1
Working Together to Make Conveyors Green
Energy Savings That MakesDollars Sense

2

• 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

3

• 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 worlds
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.   
4

• Allen-Bradley Components
• From Rockwell Automation

5

• Traditional Conveyor Drive Characteristics

• Driven by Belts, Chains, or Shafts
• Powered by Motors / Reducers
• Chains / Sprockets / Bearings
• Terminal Ends

6

• 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

7

• 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

8

• 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

9

• 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

10

• Cost Justification

Packing System Running 2 Shifts (16 hrs / day)
MDR Conveyor
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

• 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

11

• 12 Up Front Initial Investment

Packing System Running 2 Shifts (16 hrs / day)
MDR Conveyor
Traditional Conveyor
System Turn-Key Price 280,000
System Turn-Key Price 315,000
Difference 35,000 12.5 Up Front Initial
Investment
12

• Energy Usage Calculations

Packing System Running 2 Shifts (16 hrs / day)
System Parameters for Horse Power and Run Rate Calculation System Parameters for Horse Power and Run Rate Calculation System Parameters for Horse Power and Run Rate Calculation System Parameters for Horse Power and Run Rate Calculation System Parameters for Horse Power and Run Rate Calculation System Parameters for Horse Power and Run Rate Calculation

Conveyor Length 600 feet
Zone Length 24 inches
Conveyor Speed 100 ft / min
Carton Rate 15 carton / min
Live Load 20 lbs / ft
Precision Bearings Y Y / N
Utility Location Anywhere, USA

Total Weight of Load 40 lbs
Roller Run Time 1.2 sec / carton
Roller Run Rate (RRR) 18 sec / min
Cost per kWhr 0.1320 / kWhr
   
Each motorized roller runs 18.00 seconds (RRR) out of each minute to achieve a 15 CPM Rate! Each motorized roller runs 18.00 seconds (RRR) out of each minute to achieve a 15 CPM Rate! Each motorized roller runs 18.00 seconds (RRR) out of each minute to achieve a 15 CPM Rate! Each motorized roller runs 18.00 seconds (RRR) out of each minute to achieve a 15 CPM Rate! Each motorized roller runs 18.00 seconds (RRR) out of each minute to achieve a 15 CPM Rate! Each motorized roller runs 18.00 seconds (RRR) out of each minute to achieve a 15 CPM Rate!

13

• Energy Usage Calculations (16 hours per day)

Traditional Conveyor Packing System
Continuous Running Conveyor Parameters Continuous Running Conveyor Parameters Continuous Running Conveyor Parameters Continuous Running Conveyor Parameters Continuous Running Conveyor Parameters Continuous Running Conveyor Parameters Continuous Running Conveyor Parameters Continuous Running Conveyor Parameters Continuous Running Conveyor Parameters Continuous Running Conveyor Parameters

3 Phase Voltage 460 V AC Motor Specifications Motor Specifications Motor Specifications Motor Specifications Motor Specifications
Single Motor FLA 3.1 Amperes 460V AC 460V AC 460V AC 230V AC Efficiency
Motor Power Factor 77 HP Power Factor FLA FLA Efficiency
Motor Efficiency 82.5 0.5 63.0 1 2 74.0
Motor Count 12 0.75 60.0 1.5 3 75.5
1 71.0 1.7 3.4 78.5
Total Amperage 37.2 Amperes 1.5 72.0 2.5 5 78.5
Total Kilowatts 22.8212 kW 2 77.0 3.1 6.2 82.5
Total Energy 3.73 kWhr 3 82.0 4.1 8.2 84.0
Total Energy w/ Efficiency Total Energy w/ Efficiency 4.52 kWhr 5 80.0 6.6 13.2 85.5
Calculated Total HP 5 HP 7.5 77.0 10.4 20.8 87.5
Effective Belt Pull 1190 lbs
Effective HP 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
14

• Energy Usage Calculations (16 hours per day)

MDR Conveyor Packing System
Motorized Roller Conveyor Parameters Motorized Roller Conveyor Parameters Motorized Roller Conveyor Parameters Motorized Roller Conveyor Parameters Motorized Roller Conveyor Parameters Motorized Roller Conveyor Parameters Motorized Roller Conveyor Parameters Motorized Roller Conveyor Parameters Motorized Roller Conveyor Parameters

Drive Roller Voltage 24 V DC Current Draw - Weight and Speed Chart Current Draw - Weight and Speed Chart Current Draw - Weight and Speed Chart Current Draw - Weight and Speed Chart
Single Roller Current Draw Single Roller Current Draw 0.75 Amperes Weight lt 45 lbs Weight lt 45 lbs Weight 55 - 64 lbs Weight 55 - 64 lbs
Speed (FPM) Amps Speed (FPM) Amps
Roller Speed 100 ft / min lt 100 0.75 lt 100 1.3
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
Single Roller Energy 0.0054 kWhr Weight lt 45 lbs Weight lt 45 lbs Weight 55 - 64 lbs Weight 55 - 64 lbs
Total Energy Used 1.62 kWhr Speed (FPM) Amps Speed (FPM) Amps
Total Drive Roller Count Total Drive Roller Count 300 lt 100 1.1 lt 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
15

• Energy Savings

Packing System Running 2 Shifts (16 hrs / day)
Traditional System
MDR System
Cost Per Month 104
Cost Per Year 1,248
1,466
17,592

Savings Per Month 1,362
Savings Per Year 16,344
16

• Rise in Cost of Energy over the last decade

Cents per Kilowatt hour
Rate Increase From 2004 to 2008

• Data provided by the Official Nebraska
  Government Website www.neo.ne.gov

17

• 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.
18

• Traditional Conveyor Maintenance

• Lube Drive Chains
• Check Belt Tracking / Re-Lace Belting
• Grease Bearings in TEs Drives
• Change Oil in Reducers
• Monitor Drives
• Tension Drive Chain

19

• MDR Conveyor Maintenance

• Occasionally replace faulty rollers
• Occasionally replace faulty cards
• Check Power Supplies

20

• Traditional Conveyor Guarding Safety

• Drive Belts
• Chains and Sprocket
• Exposed Terminal Ends
• Roller pinch points
• E-Stops in Associate Accessible Areas

21

• MDR Conveyor Guarding Safety

• Dont trip over it while you marvel at how
  quiet it operates.

22

• Other Competitive Advantages

• Cost of Integration
• Reduced Field Wiring Install Time and Materials

• Feature Rich Design
• 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

23

• Application Examples - Case sealer operation

24

• Application Examples - Audit and pack work
  station

25

• Application Examples - 20 cpm pick zone sort
  modules

26

• Application Examples - MDR double-wide gate

27

• Application Examples Value-add work stations

28

• Application Examples - Take-away from sorter

29

• Application Examples - Accumulation

30

• Application Examples Accumulation on an Incline

31

• Questions?

32

• Common Customer Questions (hidden Slide)

• Are clients willing to spend a premium in order
  to take advantage of the potential energy
  savings?
• Are there any obvious bench mark scenarios that
  would identify the ideal application for
  AutoRoll motor driven roller conveyor?
• Is it possible to accumulate product on inclines
  or declines with AutoRoll?