solutions magazine volume2

7/31/2019 SOLUTIONS Magazine Volume2

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Cover: PG

Contents Number 2Solutions Magazine Featuring Baldor, Dodge & Reliance Products WWW.BALDOR.COM

2 Briefings

4 A new Black-Start System Featuring Baldor Generators, Means the City of Coffeyville Will Never

Be Left in the Dark

10 Distributing the GoodsAutomotion Partners with Baldor to Deliver Value

16 Rock Solid SolutionsBaldors System-1 Helps Crisp Industries Convey Success

22 Feed Plant OEM Searches for Top Quality Supplier Finds It in Dodge de Mexico

28 New 501 Baldor Reliance Catalog

Now Available

Baldors mission is to be the best (as determined by our customers) marketers, designers and manufacturersof industrial electric motors, power transmissionproducts, drives and generators.

Solutions Magazine is published by the Marketing Communications Department of Baldor Electric Company.www.baldor.com


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2 | Solutions Magazine | Number 2

Better performance and reliability arethe inspirations behind Baldors newand improved Washdown motors anddrives. Baldors All-Stainless Washdown,Paint-Free Washdown and Standard Washdown Duty motors are wellsuited for applications requiring high-pressure cleaning with caustic solution. These choices allow customers to selectthe right product for the amount of protection required.

Baldors new SSE Washdown Duty All-Stainless motors are designed toperform longer than any other industrialelectric motor available today. Thismotor, with its unmatched quality and superior reliability, is built to withstand the most corrosive and causticapplications. The Super-E premiumefficiency design of the SSE meetsor exceeds NEMA Premium efficiency levels, providing energy savings,lower temperature rise and increasedmotor life.

Baldor Reliance Paint-Free WashdownDuty motors are designed forapplications where use of caustic cleaningsolutions and regular high-pressure washdowns may compromise the surfaceof a painted motor. Features includespecial processed cast endplates; stainlesssteel motor frame, base, shaft and

hardware; encapsulated windings; anda labyrinth seal on the drive end shaftextension to protect motor bearings.

The autophoretic primer and epoxy paint system on Baldor Reliance Washdown Duty motors makes thefinish coat five times more resistant to

corrosion and chipping. These motorspass 500 hours in a salt spray booth per ASTM B117. FDA approved epoxy powder coating is electrostatically applied, inside and outside, for thoroughcorrosion prevention and long lastingfinish. This motor is also available inBaldors Super-E premium efficientdesign that delivers both reliability andenergy cost savings.

Baldors VS1SP WashdownInverterDrive uses a traditional inverter V/Hz control technology. Its easy setup, quick startup, and right-out-of-the-box operation make it among themost popular variable speed motorcontrols available. This drive is ideal forapplications where multiple motorsare operated simultaneously from onemotor control.

The VS1GV Washdown VectorDrive is a high-performance vector drive thatoffers three modes of operation: closed-loop, encoderless, or the traditional V/Hz

to control motor speed and torque with precision and the responsivenessneeded to accomplish the mostdemanding applications.

Baldor offers the widest variety of Washdown Duty motors and drivesavailable from stock. Motors may be

selected with the required voltage,horsepower, speed and mounting forthe application. Plus, Baldor also offers your choice of Baldor Reliancepermanent magnet DC motors,SmartMotor and servo motors with Washdown Duty construction. No othercompany offers more Washdown Duty products than Baldor.

B aldor r eliance W ashdoWn d uty M otors and d rives o ffer f eatures ,c hoice and a vailaBility


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Number 2 | Solutions Magazine |

Ideally suited for large bulk handlingconveyors, Baldor's new Dodgehydraulically-assisted ISAF bearing iseasy to install and remove, features twosuperior sealing systems, and has housingsand inner units made of ductile iron foradded strength.

The Dodge hydraulically-assisted ISAF(8 and larger shaft sizes) utilizes

a built-in hydraulically-assisted,adapter-mounted installation andremoval system. To install, simply

slip the bearing on the shaft and apply hydraulic pressure to position the bearingon the adapter sleeve. Instead of thetime consuming process of mechanically rotating a lock nut, the hydraulic systemquickly and easily pushes the bearinginto position.

Once installed, the full shaft contactoffered by this unique mounting system

n eW d odge h ydraulically -a ssisted Bearing o ffers u sers e asy installation and r eMoval

reduces or eliminates fretting corrosion. To remove, simply apply pressure to thedismount piston to push the bearing off the adapter sleeve. No feeler gauges orspecials tools are needed for installationor removal.

Factory assembled, sealed and lubricatedthe Dodge hydraulically-assistedISAF features dual sealing systems to

ensure longer bearing life by reducingcontaminants. A triple lip inner-boreseal, in combination with re-greasableLOR aluminum outer seal with anO-ring, ensure that contaminants cantpenetrate the bearing cavity, makingit the ideal bearing for dirty and dusty harsh environments.

An ideal replacement for SAF pillowblocks, Baldor's Dodge large bore ISAF iavailable in sizes ranging from 8 to15 inches.

e xtra t ough d odge r educer n oW a vailaBle

are power matched for optimumperformance at a lower installed cost.

In sizes over 390,000 lb-in, the MAGNAGEAR XTR features theproven Dodge planetary design,providing a compact, durable, light weightand economic solution for high

Baldor's Dodge MAGNAGEAR XTRis an extra tough reducer that has beenengineered to offer maximum reliability and superior performance in tough, hightorque applications.

Designed as a global product, the MAGNAGEAR XTR is available withparallel shaft or right angle configurationsand will initially offer torque capacitiesup to 920,000 lb-in. The modular designof the product allows for multiplemounting configurations and can beused with a variety of soft startmechanisms, making it ideal for a variety of conveying applications.

Designed to meet or exceed AGMA and international standards, this heavy duty, cast iron product features gearingthat is carburized, hardened, andprecision ground. Tandem HBNR lipseals are standard for extra protection,all bearings exceed AGMA standardsfor L10 life, and all components

torque applications.

A complete line of engineeredaccessories are available including,internal lift-off style backstops, coolingsystems, rigid couplings, torque arms,swing base mounts, tunnel housings,and baseplates.


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volumes of goods from all over the world,and then track them through a complexprocess of inspecting, separating and sortinbefore products are ultimately shipped outagain to reach the consumer.

Established in 1967, Automotion hasearned a reputation as an innovativeconveyor manufacturer and provider of integrated package handling systems.Davis says their goal is to increase theefficiency of large warehouses anddistribution centers by providing costeffective, user-friendly, low maintenanceconveyor systems.

Our focus is to provide solutions toimprove the productivity and the bottomline of our customers who are tryingto get product to their stores andultimately to their customers, says DavisWe want to help them decrease costs,and increase through-put, all in aneffort to help them be more competitiveand profitable.

It All Starts with Engineering Because each system is customdesigned, Davis says all their work starts with engineering. By listeningto needs and goals of the customer, Automotion engineers take those ideas

and deliver a unique solution that willmeet specific requirements.

Ninety-five percent of the sheetmetal parts used on the conveyors aremanufactured by Automotion in a lean,made-to-order process. They even makeall their own rollers, more than a millionper year. Davis says its like building andthen working with a giant erector set.

Unlike some machines that arebuilt and installed as one piece, these

conveyor systems are designed so thatmodular components can be deliveredto the customer site where they are puttogether, says Davis. We take all thesepieces and build something unique forthat customer, a system that can be

Left: Automotion designs and builds uniqueconveyor systems for each customer with thegoal of efficiently moving goods throughout adistribution warehouse.


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...we appreciate the value of Baldors product, delivery and service

Merle Davis, President, Automotion

configured to perform any transporting,merging, or diverting operation efficiently moving goods throughout theirdistribution warehouse.

Choosing a Trusted Partner

Davis believes Automotion is successfulbecause of the companys ability toconsistently provide customers top quality,good value, and good service. Whenlooking at key suppliers, he says hechooses companies that provide thosesame things. Thats why Automotion haschosen to partner with Baldor.

Baldors value proposition is to strive tobe the best as determined by customers,explains Davis. We know its not just

a slogan, it really is something that thecompany lives by. And we appreciate the value of Baldors product, delivery andservice.

For the past 40 years Automotion hasinstalled Baldor motors on the majority of their equipment. This long standingmotor partnership made it easy for Automotion to switch to Baldors900 series LF style worm gear speedreducers after facing quality issues with a competitors gear box.

When we couldnt get quality issues

resolved, we began to look for another vendor, explains Davis. At that sametime, Baldor was launching their newgear product line, which made it aneasy choice for us. Based on ourrelationship, we knew that addingBaldor reducers would be a great fit.

As a trusted partner, Automotiondepends on Baldors ability to respondquickly to meet the demandingdeadlines they often face from theircustomers. Sometimes we have littleor no time to get everything togetherfor a project, but we can count on

Below: Baldor motors with 900 Series LF style wormgear speed reducers are installed on the majority of Automotions conveyor equipment.


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Because of Automotions commitment to quality, thecompany offers extended warranties. Automotioncan make this offer because they have confidence intheir equipment, including the Baldor motors andgear boxes.


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Baldor to get us the products, saysDavis. You only have to be short onecomponent to make the project late.But Baldor has been outstanding inproviding on-time delivery, and they never have been the issue in delaying

a project.Quality is the Key to Success While meeting demanding deadlinesis one reason for Automotions success, John Hejmanowski, distributor sales vice president, says providing quality is even more important. Because of Automotions commitment to quality, hesays the company is able to offer extended warranties, differentiating their company in a competitive market.

Below: Baldor motors and worm gear reducerscan be found on a variety of Automotions sortationequipment. Depending on customer requirements,this equipment is capable of sorting from five to 250cartons per minute.

We can make this offer because wehave full confidence in our equipment,including the Baldor products, saysHejmanowski. Offering customers thisadditional value is a big advantage forus. If we didnt believe in the Baldorproducts, we wouldnt be able to makethe offer.

Automotion has built conveyor systemsfor some of the best known companies

in the U.S., including Home Depot, Williams-Sonoma, Amazon.com,Levi Strauss, Crate & Barrel, Staples,and Sports Authority. And while

Hejmanowskis proud of their list of customers, he says hes more proud thatmany of their customers come back, timeand time again, when they want to expandor build new operations.

The repeat business that we get is areal bench-mark of our success, saysHejmanowski. When a customer keepscoming back, you know you are doingsomething right. We strive to serve our

customers the way Baldor serves us. If wecan always offer customers good quality,good value, and good service, we knowthat success will follow.

We strive to serve our customers the wayBaldor serves us.

John Hejmanowski, distributor sales vice president, Automotion


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A New Black-Start System,Featuring Baldor Generators,

Means the City of

Coffeyville WillNever Be Left In

The Dark Investing 2 million dollars on a system you hope you neverhave to use may seem odd, but it made perfect sense to thecity of Coffeyville, Kansas. The city wanted to ensure thattheir community would never be left in the dark, no matter what Mother Nature threw at them. Thats why they built ablack-start generation facility, featuring two Baldor 2,000 kWgenerators that would start their main power plant in the eventof the loss of electric power from the transmission grid.


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The Coffeyville Power Plant, a gas firedfacility, began serving the community in1901. But as natural gas prices began torise in the early 80s, older plants like this were no longer an economical way togenerate power. Instead, the city began

to purchase power from the Grand RiverDam Authority (GRDA), through anational transmission grid that suppliespower to municipalities throughoutthe Midwest.

Over the past several years, theCoffeyville plant was only powered upduring peak usage periods, generally inthe hot summer months. However, sincethe plant actually needs electricity to startup, city officials wanted to make sure they

could run the plant, even if the grid wentoff line.Bernard Cevera, the director of electricutilities for the city, says thats whenthe city decided to have the black-start

facility built. We wanted this system asour insurance policy, says Cevera. A black-start unit provides a reliable powersupply, allowing us to serve our citizensand prevent the critical public healthand safety issues that develop when a

community loses electricity. With the goal of making their plantreliable 24/7, the city awarded thecontract to build the black-start facility to Emergency Power Systems, basedin Tulsa, Oklahoma. EPS has been in

Above: Coffeyville's "black-start" generation facility features two 2,000kW Baldor diesel generators that will be able to start the city's main power plant inan emergency.


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EPS packaged two 2,000kW Baldordiesel generators with a 15 kV customparalleling switchgear system, complete with touch screen control. The 16cylinder engines on the generators arefueled by a 25,000 gallon external maintank. The project was completed in 12months, from the design phase all the wayto final commissioning.

While EPS had the systems knowledgeplus the experience handling turn-key projects like this one, Haynes is quick toshare credit for the success of the project with Baldor generator engineers. Thedirect and easy access to Baldor engineer was critical for this project, says HaynesThis was a big project for us and it was important for us to interface withthe Baldor team. We never wasted time waiting for answers because Baldor was very responsive to our needs, enabling usto stay on track and finish the projecton time.

Working with a manufacturer that is willing to customize their product basedon customer needs was another reasonfor the success of the project accordingto Haynes. Since the generators are tiedinto the sub-station, Haynes requestedsome modifications be made to the units,including a request for medium voltagealternator that could be packaged with thecustom switchgear.

What ever I needed, says Haynes,Baldor was willing to do it because they are not a cookie cutter manufacturer.I have worked with other manufacturersthat are reluctant to make changes oroffer any customization. But when I ask Baldor for something different, they tellme they can do it.

With the project complete, theCoffeyville plant will be operated in a newmode called ready state, meaning that

Left: EPS packaged the two Baldor generators with a 15kW custom paralleling switchgear systemcomplete with touch screen control.


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Number 2 | Solutions Magazine | 1

they will be able to be up and running within 24 hours notice from GRDA.By having the flexibility to start theplant at any time, under any conditions,

It's clear that adding the black-start generators makes our plant the most valuable asset the city owns.

Bernard Cevera, director of electric utilities, Coffeyville, Kansas

the city is helping the GRDA meet itsregulatory obligation for reserve power.Its a service the GRDA is willing topay for. Building the black-start plantmeans that our town will be ready for any disaster, but it also means the town hasa new revenue source, explains Cevera.By guaranteeing that we are in a ready state, the city now receives $220,000per month in a capacity payment fromthe GRDA.

Cevera says they havent yet calculatedthe other benefits they may gain withload shedding and peak shaving strategies.The flexibility to produce power willoffer us additional benefits that we havenot quantified, says Cevera. But its clearthat adding the black-start generatorsmakes our plant the most valuable assetthe city owns.

In the months since the black-start unit was commissioned, the city has not hadto start the facility for any emergency needs and Cevera says thats just the way he wants to keep it. However, thesystem is tested every three weeks tomake sure that everything is workingproperly. We validate the system on aregular schedule by actually exportingkW to the grid, says Cevera. We havenot once been disappointed by thesystem in fact we are very pleased.

The black-start works as well as it looks.

Below: The 16 cylinder engines on the two Baldorgenerators are fueled by a 25,000 gallon externalmain tank.



Baldors System-1 HelpsCrisp Industries Convey Success

F or the past 31 years John Crisp,the president and owner of Crisp Industries, has focused hiscompany 100% on the aggregateindustry and the needs of the people

who run quarries.

ROCK SOLIDSOLUTIONS


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I want products that will perform and lastlong after the warranty period is over, and

thats the honest reason why I choose

Baldor

Reliance and Dodge products. John Crisp , president and owner, Crisp Industries

From the companys humble beginnings with one welding truck, Crisp Industrieshas grown into a one-stop shop for theaggregate industry, offering completematerial handling systems includingconveyors, plants, bins, feed hoppers,

and steel fabrication. Crisp also specializesin large turn-key projects, managingthe design and construction of newaggregate facilities.

Based in Bridgeport, Texas, CrispIndustries has designed, fabricated, anderected a multitude of aggregate plants across the country. Crisp believes his

company has been successful because of his longstanding philosophy of offeringtop quality. We are not in the businessto build the cheapest plant, says Crisp.I know I could find ways to lower the

price, like installing less expensive - lower

quality products, but then what do youhave at the end of the day. So I might be alittle higher, but the plant I build will stillbe running in 30 years.

Crisp describes his customers as partners,making it clear that hes not interested

Below: Throughout more than three-miles of conveyance in the Marble Falls, Texas facility youllfind only Dodge mechanical products and Baldor-Reliance motors. Size 14 TXT reducers, 250 HPmotors, Mine Duty Extra pulleys and Type E

bearings can be found on this load out conveyor.


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in just making a one time sale and then walking away. And thats why I chooseto use what I call Cadillac products,explains Crisp. I want products that willperform and last long after the warranty period is over, and thats the honest

reason why I choose Baldor

Reliance andDodge products. Based on my experienceI know that these products are the mostdurable and reliable.

When it came time for Crisp Industriesto design and build a new plant forCapitol Aggregates, there was no question which mechanical and motor products would be used. Throughout the morethan three-miles of conveyance in the Marble Falls, Texas, facility youll findDodge TAF and Type E bearings,

Dodge take-up frames, Dodge pulleys,Dodge TORQUE-ARM reducers,Dodge belts, and Baldor Reliance motors.

As much as John Crisp is sold on selectingBaldor products, hes an even biggerbeliever is using the services providedby Baldors System-1 team.

Crisp views the System-1 team as anextension of his company, working alongside Crisp Industries employees to geta project done right. To me this is thebiggest selling point for System-1, adedicated team working to make surethat we get the right products packagedthe right way, delivered to us at the jobsite when we need them, says Crisp. Allthe crew in the field has to do is take onepre-assembled system off a pallet, bolt it

on the conveyor and its done. Its a hugetime savings for us.

Mike Parsons, Crisp Industries projectestimator/hardware specialist, saysSystem-1 also saves them time on thefront end of the project. Because theSystem-1 team has a depth of knowledgeon motor and mechanical products usedon conveyor systems, they save us a lot oengineering time, says Parsons. I donthave to go through and choose every product and match horsepower because

they know how to do the job and give us what we need. This help frees me up to work on other aspects of a project.

System-1 offers pre-engineeredpackaged solutions that help simplify the design, quotation and orderprocessing of multiple mechanical andelectrical products, while ensuring thatall the components are properly matched.

Above: Crisp Industries values the pre-engineeredpackaged solutions from Baldors System-1 team. This Dodge Slide Lag pulley and Dodge Type Ebearing comes pre-assembled and ready to mount.

Left: Pre-engineered drive and tail conveyorassemblies are delivered on pallets to job sites,saving Crisp Industries time and money.


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And Parsons says while other companiesmay offer packages, they are not ascomplete as those offered by Baldor.Other companies try to packageequipment, but it ends up coming inseveral boxes and we still have to putmost of it together, explains Parsons.Others just dont offer the same

level of service, plus, other companiescant compete with the quality of Baldor Reliance and Dodge products.

Parsons says his close workingrelationship with the Sysem-1 team wasa critical part of recovering and gettingback on schedule after the Marble FallsQuarry was flooded prior to completion.Nearly 21 inches of rain fell, and when aberm broke, water filled the quarry floorcovering dozens of products.

I sent a list of all the equipment thatneeded to be replaced to System-1 andthey began to immediately locate all of the products we needed, said Parsons.It was a real team effort and we quickly got everything delivered to the job site so we could still meet the project deadlines.Because we worked together, we got the job done.

According to Crisp, the willingness of theSystem-1 team to work so closely withhis company to keep the project on tractafter the flood is just one more exampleof why he chooses to work with Baldor.He describes the completed project asa tremendous success a success that isshared by both companies.

The Marble Falls project has been agreat project for all of us, says Crisp.Ive been in the business more than 30 years and I think Im a pretty good judgeof operations, and I feel that this is a verynice plant. But more importantly, Capitol Aggregates tells us that they are very pleased and proud of this facility.

Left: Crisp Industries selected the Dodge MineDuty Extra pulley and Dodge TAF bearing forthis primary conveyor at Capitol Aggregates new Marble Falls quarry.



T wenty-eight years ago the Diazfamily opened a small metalfabrication shop out side the

city of Guadalajara, located in central Mexico. Over the years as their businessexpanded, they added employees andstarted taking on bigger and bigger

projects. Like any successful businessowners, the family had a clear visionof what they wanted their company,IMDHER, to become. This past yearthat vision became reality when they completed the largest fully automatedpre-mix feed plant in Mexico.

Finds it in Dodge de Mexico

Feed Plant OEMSearches for Top

Quality Supplier...

IMDHER chooses Dodge QUANTIS gearmotors to moveanimal feed ingredients in pre-mix mills across Mexico.


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We had the chance to review catalogs,meet sales people, and understand what

kind of service we would receive. Based onall the information, we chose to work with

Dodge de Mexico and select the Dodge productEfren Diaz, IMDHER production manager

Its a story of success that entrepreneursall over the world can appreciate; hard work, a willingness to take some risks,and making strategic decisions about thecompanies you choose to partner withand the products you select to use on your equipment.

While IMDHER might be known today as an OEM than can design and buildlarge scale feed plants that may includesilos, grain elevators, and all of thedifferent conveyor systems required tomove grain throughout the process, theirpath to success was not always easy. Forexample, when they decided to position

their company as a first tier OEM, oneof the first obstacles they faced was theperception that a Mexican OEM couldntbe as good as an OEM from the U.S.,or Europe.

But Eduardo Diaz, IMDHER projectengineer, says once they had the chanceto present the companys capabilities, they

began to get opportunities. One of ourstrengths is that we take full responsibilityfor the entire project, says Diaz. Weset ourselves apart from the others by offering a turn-key service, from thedesign all the way to completion.

With the anticipation of growth,IMDHER officials felt the time was right

Below: The success of standardizing on Dodgeproducts has led IMDHER to more recently selectthe Baldor Reliance brand as their motor standard.


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to standardize on one brand and onesupplier for the variety of mechanicalproducts they needed. According toIMDHER production manager, EfrenDiaz, they wanted to find a partner that would grow along with them, plus find

a product brand that stood for quality and performance.

The task became a little easier whenthe company began to bid on their firstlarge project several years ago. Whatthey learned, according to Eduardo Diaz,is that their potential customers had aclear preference for Dodge brand gear

reducers and bearings. The customerstold us they were happier with Dodgeproducts, that they felt confident thatDodge products would perform and wouldnt fail, says Diaz. The otherbrands didnt offer the same quality thatcustomers were demanding for theselarge scale, high-profile projects.

Efren Diaz says while the customerfeed back was clear, they felt it was alsoimportant to take a closer look at thecompany and people that would standbehind the product. We looked closely at several brands we had used over the years and the companies that we worked with, says Diaz. We had the chance toreview catalogs, meet sales people, andunderstand what kind of service we wouldreceive. Based on all the information, wechose to work with Dodge de Mexico andselect the Dodge product.

Today youll find a variety of Dodgebearings on IMDHER projects, includingSC, SCM SAF, TAF, Type E, and S2000bearings, plus TORQUE-ARM reducers. But the reducer that IMDHERhas used most often in their projectsis the Dodge QUANTIS

In-LineHelical (ILH) gearmotors that are builtat Baldors Dodge de Mexico plant inGuadalajara.

Nearly 600 QUANTIS ILH integralgearmotor units have been installed atIMDHER projects across Mexico overthe past three years. Efren Diaz says notonly are they more than pleased withthe products performance, they alsobenefit because the units are built locally.Getting the product configured the way we want and in the ratios that weneed is ideal, says Diaz. Getting theproduct quickly because its built here inGuadalajara is a real advantage for us.

Standardizing on Dodge products hashelped IMDHER meet their customersdemand for quality, but the decision hasalso made an impact on IMDHERsengineering workload. According to

We get great service and they [Dodge de Mexivery easy to work with. Product is important, b

the people and the service that make a differeEduardo Diaz, IMDHER project engineer

Left: Currently the QUANTIS build center inEl Salto, Jalisco builds QUANTIS ILH reducersexclusively for the Mexican market in sizes 38 to88 and with ratios from 5:1 up to 125:1. They candeliver units in less than 48 hours, in many casesthe same day.


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Efren Diaz standardization hashelped save them a tremendousamount of time in the designphase of a project. We nowhave standard dimensions forproducts which means we dont waste time changing designs,says Diaz. In the past when weused a variety of products, wehad to spend too much timemaking corrections.

While the Diaz family is pleased with their product selection, they are even more complimentary of the employees at Dodge de Mexico. Eduardo Diaz says they count on the local support, notonly from the sales engineer that works with them, but also fromthe entire team at the Baldorplant. We know that they sometimes work extra hours for us when we need help, explainsDiaz. We get great service andthey are very easy to work with.Product is important, but its thepeople and the service that makea difference.

Pleasing the customer by offering quality products andexceptional local service is the way the Diaz family describestheir business. Its also the way they talk about Dodge de Mexico, and why they plan tocontinue choosing Dodge andBaldor Reliance products asthey take on their next challengeof expanding their business toSouth America.

Right: Nearly 600 Dodge QUANTISILH integral gearmotor units have beeninstalled at IMDHER projects across Mexico. In this application the unitspower hoppers, moving a variety of ingredients to the mixers.


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