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
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.

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
Traditional
Conveyor
Conveyor

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

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
Traditional
Conveyor
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

feet
inches

100
15
20

ft / min
carton / min
lbs / ft

Y
Anywhere, USA

40
1.2
18
0.1320

Y/N

lbs
sec / carton
sec / min
$ / kWhr

Energy Usage Calculations (16 hours per day)

Traditional Conveyor Packing

System
Continuous Running Conveyor Parameters
3 Phase
Voltage:
Single Motor
FLA:
Motor Power
Factor:
Motor
Efficiency:
Motor Count:

12

Total Amperage:
Total Kilowatts:
Total Energy:
Total Energy w/
Efficiency
Calculated Total
HP:
Effective Belt
Pull:
Effective HP:

460

V AC

3.1

Amperes

77

HP

82.5

0.5
0.7
5
1
1.5
2
3

63.0%

74.0%

60.0%
71.0%
72.0%
77.0%
82.0%

1.5
1.7
2.5
3.1
4.1

3
3.4
5
6.2
8.2

75.5%
78.5%
78.5%
82.5%
84.0%

80.0%

6.6

13.2

85.5%

7.5

77.0%

10.4

20.8

87.5%

37.2
22.8212
3.73
4.52

Amperes
kW
kWhr
kWhr

HP

1190
3.8

lbs
HP

One Shift (8 hrs / day)

Motor Specifications
230V
460V AC
AC
Efficiency
Power
Factor
FLA
FLA

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:

Roller Speed:

24

V DC

0.75

Amperes

100

ft / min

Current Draw - Weight and Speed Chart

Weight < 45 lbs

Weight 55 - 64 lbs

Speed (FPM)

Amps

Speed (FPM)

Amps

< 100

0.75

< 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

0.0054

kWhr

Total Energy Used:

1.62

kWhr

Total Drive Roller Count:

300

Single Roller Energy:

One Shift (8 hrs / day)

Cost Per Month:

Cost Per Year:

$
52
$
625

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

Two Shifts (16 hrs / day)

$
104
$
1,250

Energy Savings
Packing System Running 2 Shifts (16 hrs
/ day)

Cost Per
Month:
Cost Per Year:

MDR
System

$ 104
$ 1,248

Traditional
System

$ 1,466
$ 17,592

Savings Per Month:

$1,362
Savings Per Year:
$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)

System Turnkey Price

MDR
System

Traditional
System

$315,000

$280,000
10 Year Energy Cost (16 hours per day)

$12,480

$175,920
Total

$327,480
Savings After 10 Years
$128,440

$455,920

*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

Lube Drive Chains
Check Belt Tracking / Re-Lace
Belting
Grease Bearings in TEs &
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

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

MDR Conveyor Guarding & Safety

Dont 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:

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?