Motion and Gates turning waste into wins at recycling factory

A leading Australian recycling company found itself grappling with persistent downtime and reliability issues plaguing one of the factory’s pressure screens. With customers Australia-wide relying on it for the delivery of corrugated cardboard boxes and paper products, it was critical to get the factory back up and running. Motion’s National Business Development Manager – Quarrying, Brad Hudson, was brought in to identify and promptly solve these problems.

Motion conducted a joint analysis with Gates®, a leader in fluid power and power transmission, to uncover the root cause of the pressure screens issue. The analysis traced the issue back to an under-designed drive system, while inefficient belts were found to be exacerbating the problem.

To address this, a strategic decision was made to switch to Gates® Predator™ V-belts, known for their high-power density, which exceeds that of many competing V-belts. The belts are engineered as original equipment quality replacement belts for heavy-duty applications, making them an ideal choice for industries like recycling where reliability and durability are critical. Their design ensures full contact with pulley grooves for uniform cord loading, uniform wear, and increased belt life. These belts can tolerate up to 2.2 times more power than a standard equivalent size V-belt, thanks to their premium rubber compound and aramid tensile cords.

This solution was planned for implementation during a scheduled shutdown day, aiming to resolve the issue without disrupting regular operations. Motion’s team, in collaboration with Gates®, undertook the task of replacing outdated components. The process involved meticulous planning and execution, ensuring optimal drive design, alignment, and correct belt tensions. This intricate overhaul was not just a one-off replacement, but a strategic move to enhance long-term reliability. Compared to traditional V-belts, the Predator™ delivers twice the power with half the number of belts. This saves money for customers, boosts productivity, and extends the life of their machinery.

The partnership between Motion and Gates® proved crucial in addressing the challenges at the recycling plant. This combined Motion’s expertise in material handling processes and Gates®’ innovations in power transmission, leading to a swift identification and implementation of a necessary solution. By identifying the Predator™ V-belts as the perfect solution, their collaboration showcased the strength in combining materials handling knowledge with manufacturing advancements to solve industry problems.

The collaboration’s impact was immediately evident, significantly enhancing the drive system’s performance at the recycling plant. Through precise adjustments to misalignment and tensioning, the initiative drastically reduced wear and tear. This not only prevented future breakdowns but also bolstered operational stability across the board.

Adopting a strategic approach, Motion and Gates® delivered more than just immediate repairs. The sturdier Predator™ V-belt reduced maintenance duties and therefore increased uptime for the customer. The Predator’s™ significant power boosted throughput while its lightweight design reduced energy costs for the customer.

This energy reduction also helps with efforts in sustainability, giving the customer a point of difference when advertising to their customers.

This illustrates the value of strategic partnerships in overcoming industry challenges. The joint effort between Motion and Gates® highlights the importance of combining technical skills with innovative approaches to improve operational efficiency. Their success sets a standard, demonstrating that collaboration can lead to significant, sustainable improvements in performance.