delivering cost savings - brammer pt brochure march17.pdf · £11,000 timken quick-flex coupling...

Mechanical Power Transmission:Delivering Cost Savings

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Mechanical Power Transmission: Delivering Cost Savings

Brammer is the UK and Europe’s leading Mechanical Power Transmission supplier. Selling over £20 million worth of Mechanical Power Transmission products every year, we offer the largest and most comprehensive range in the UK, including:

Mechanical Power Transmission Experts

Sourcing the right quality Mechanical Power

Transmission product is vitally important to ensure the

optimum performance and trouble free operation of your

production equipment. As the authorised distributor for

the world’s leading brands, including Gates, Renold,

Tsubaki, Timken, Optibelt, Mecro and IPL, Brammer

offers the latest innovative products including Gates

new Quad Power 4 (service free and energy efficient)

and Tsubaki Lambda lube free chain. Mechanical Power

Transmission technology has advanced considerably

over recent years; we provide the latest product

knowledge and additional technical support to our

customers. We can also provide technical support

and advice direct from the manufacturer if necessary,

including specific guidance and in-depth application

specific expertise.

As the leading Mechanical Power Transmission

distributor, we hold a comprehensive range of stock

within our National Distribution Centre and our regional

sales and service centres to support your manufacturing

needs 24/7.

Belts

Chains

Conveyor belting

Conveyor chains

Couplings

Clutches

Ironware

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Why Buy From An Authorised Distributor?By buying from Brammer, an authorised distributor

for the leading Mechanical Power Transmission

products, you can be assured of not only the warranty

and traceability of all our products supplied, but the

latest design and specification, minimising the risk

of reworked, second-hand, poor quality components

from unauthorised sources.

Brammer understands the importance of maintaining

production line integrity and the financial impact

of downtime resulting from breakdowns. Also,

our guaranteed quality assurance, consistent part

numbering, total product traceability and a full

manufacturer’s warranty far outweighs any short term

purchase savings.

Highest Quality Mechanical Power Transmission Products for Longer Life and Optimal Performance

• Wide product range from leading manufacturers,

available next day

• Latest technical innovation

• Reduced vibration and noise levels

• Lower energy consumption from efficient product

operations produce greater output and reduce CO2

emissions and energy costs

• Latest products and materials provide greater

resistance to wear

• Reduced failure and easier installation reduces

downtime and maintenance costs

• Increased output and reduced repair and

replacement costs

Access to Technical Expertise

• Exceptional product knowledge available to all

customers at all times

• Trained team of experienced professionals provide

on-site repair

• Technical support and advice direct from the

manufacturer if necessary

• If required, unique or customised Mechanical Power

Transmission products provided

Brammer’s customers enjoy a wide range of benefits by dealing with an authorised supplier:

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Brammer works with suppliers in close partnership to

help deliver cost savings worth millions of pounds for

our customers every year.

Using the right high quality Mechanical Power

Transmission products ensures optimum performance

and reduces problems with equipment, such as

misalignment and unbalance.

Sourcing the right quality Mechanical Power

Transmission product from an authorised distributor

is vitally important in providing additional benefits

including reducing downtime, extending the period

between planned maintenance programmes,

improving performance and output, reducing energy

consumption and extending the service life of

products.

Why Choose Brammer?Cost savings

Misalignment Unbalance LubricationTension

By choosing Brammer to be your MechanicalPower Transmission Partner...You Get...

Reduced energy costs

The latest product specifications

Trained technical experts and field support

The largest and most comprehensive range in the UK

Preventative maintenance programmes to reduce downtime


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Industry

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Case Studies

£44,500

£25,000

Gates Polychain and Synchronous Drive Train System

Gates Predator PowerBand Belt

Metal

Aggregate

A customer was experiencing efficiency problems with four walking

beam furnace cooling fans and wanted to improve the drive train

efficiency by replacing existing, inefficient equipment. Investigations

revealed that the existing belts on each fan fell off occasionally, required

replacing annually and needed re-tensioning four times a year. The

customer’s Improvement Engineer also wanted to improve the cooling

system’s efficiency, improve energy costs and reduce the number

of fans in use. By introducing Gates’ Polychain Carbon Belt and

Gates’ Synchronous Drive Train system, the belt efficiency improved

dramatically. The change also increased the service life on each belt

from one year to three years and reduced the need to re-tension belts.

Total savings of over £44,500 were realised, including labour costs, cost

of replacement belts and energy savings.

A leading aggregate producer was facing issues with their Primary

Crusher. It had a usual belt life of between four to six months with

a rated power transmission capacity of 195kW, but damage to the

280mmØ motor pulley meant that they were only able to run six belts

instead of the usual eight, thus reducing the life to four to six weeks.

Due to the critical nature of the application, the drive was subject to

ongoing maintenance. They spent 60 hours annually checking the

V belts and up to four hours every four to six weeks replacing

them. This led to an annual loss of production of 100 tonnes. Upon

consultation, the drive was redesigned using a matched set of Predator

PowerBand belts. As a result, the number of belts was halved whilst

the power transmission capacity increased to 225kW. This resulted in

cost savings of approximately £25,000 for the customer.

Case Study 1

Case Study 2

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£238,000 per annum Tsubaki Lambda Lube Free Chain with Top Plate Automotive

A major UK car manufacturer was experiencing production interruptions

and a short service life from a body panel conveyor chain. External

lubrication was being manually applied every three months which was

resulting in poor articulation over time because of contamination build

up on the chain. This chain also suffered from top plates coming loose

due to poor riveting. Upon inspection, Tsubaki engineers had the perfect

solution; they provided the customer with maintenance free Lambda chain

with internally lubricated bushes that require no external lubricant. High

tensile screws and thread lock adhesive was also provided to ensure the

robustness of construction required for the application, whilst offering a

quick removal of plate to allow maintenance. The Lambda conveyor chain

had an increased service life, removed the need for external lubrication,

and reduced the annual costs of the lost production.

£1,390 per annum Tsubaki GT4 Winner Chain Construction

One of Europe’s largest asphalt production plants was facing frequent

downtime and high costs due to limited lubrication access on the conveyor

drive chain. Tsubaki engineers examined the situation and recommended

the GT4 Winner chain as a suitable alternative. GT4 Winner chain

features lubrication grooves within its seamless bushes which increase

the lubrication retention. Centre sink rivets are also standard for ease of

disassembly and ‘ring coin’ connecting links for increased strength. The

application underwent a test against two competitors’ chains. The test was

1,000 hours of continuous operation and proved that the GT4 Winner chain

experienced 15% - 35% less wear elongation than the competitors’ chains.

This reduced maintenance requirement which resulted in less production

downtime and increased service life minimising costs associated with drive

chain replacement, and saved £1,390 per annum.

Case Study 3

Case Study 4


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£104,400 per annum

£36,200 per annum

Tsubaki Lube Free Neptune Chain

Tsubaki Plastic Combination Chain

Steel

Food

The quenching process at a Scottish steel mill was being hindered by

continual failure of a drive chain. High volumes of water utilised during

the quenching process removed lubrication from the chain causing

seizure, and increased chain elongation over time. Furthermore, moisture

was increasing corrosion on the chain, resulting in 100 hours of lost

production every year. Tsubaki engineers recommended the Lambda

Neptune chain. This is a self-lubricating chain with high corrosion

resistance due to a special surface treatment. Features of the chain

not only reduced maintenance costs, they also increased the chain

service life from three months to 12 months. The Lambda Neptune chain

drastically reduced lost production time to 10 hours per annum resulting

in cost savings of £104,000.

A transfer conveyor for loaves of bread in a UK bakery was regularly

experiencing plastic roller chain failure. The original chain became

brittle, resulting in uneven wear and elongation, line stoppages, damage

and the loss of entire batches. The Tsubaki Plastic Combination chain

recommended as a replacement operated successfully for 20 months

without elongation or fault, achieving zero downtime for the conveyor.

The Plastic Combination chain combines extruded plastic inner links with

stainless steel pins and outer plates. This combination has increased

strength when compared to an all plastic alternative. The bush chain

construction allows for easy cleaning of product debris and the absence

of external lubrication ensures no contamination risks.

Case Study 5

Case Study 6

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Industry£11,000 Timken Quick-Flex Coupling Metal

A steel manufacturer wanted to reduce downtime of their oil coolers

resulting from failures in the coupling linking the motor to the fan.

Previously, the oil coolers had also failed as a result of wear in the nylon

teeth of the couplings and potential defects were possible as a result

of overheating or overcooling. Additionally, the process of replacing

the existing couplings took a minimum of an hour at a cost of £4,000.

Brammer was asked to propose an alternative that would extend the life

of the current set up, and reduce downtime costs. The existing couplings

were replaced with Timken Quick-Flex with blue insert and a high speed

cover. The new couplings have been in place for a year with trouble free

operation, resulting in a saving on one cooler of over £11,000. There is

also the opportunity to install the replacement coupling on the other four

coolers resulting in an overall potential cost saving of over £45,000.

£25,755 per annum Timken Quick-Flex Coupling Food

A customer wanted consistent, reliable production output on five drink

production lines, but was experiencing difficulties due to transmission

chains, sprockets and support bearings becoming heavily corroded and

severely worn with evidence of water ingress. To increase periods between

time consuming and costly planned maintenance, Brammer engineers

recommended high load, corrosion resistant components. Even though

similar couplings normally have a three year service life, a sixth month

maintenance inspection was in place as the coupling was under a large

amount of tension and any failure could be a potential risk to employees.

Following discussions Timken’s Quick-Flex was suggested, which was easy

to fit, would allow element replacement in situ without dismantling the drive

as well as bi-monthly planned preventative maintenance. The switch was

calculated to result in cost savings of £77,265 over three years.

Case Study 7

Case Study 8


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£9,000 every four years

£13,000 per annum

Optibelt Red Power Belts

Optibelt Omega High Power Belt

Aggregate

Engineering

A customer in the aggregates sector was operating a tough crusher

drive with a set of four belts which required re-tensioning every two

months and had a lifetime of only 12 months. Engineers recommended

replacing them with a set of Red Power belts which after approximately

five years were still operating in good condition and had required no

re-tensioning during the entire time. Furthermore, the customer also

measured an average 5% reduction in power consumption since

switching to the Red Power belts. The customer calculated total cost

savings of £9,000 every four years including belt costs, maintenance and

energy savings.

An Original Equipment Manufacturer of vehicle mounted utility

machinery used a 50mm wide 8M timing belt on the power take

off. Engineers upon inspection of the set up, calculated the drive

requirements and determined that a 20mm wide Omega High Power

belt could safely transmit the required power as well. The change to

the narrower belt and pulleys required no significant redesign and

resulted in a 45% reduction in the weight of the drive as well as a 40%

reduction in total cost. The customer experienced a cost saving of

£13,000 per annum with the replacement belt.

Case Study 9

Case Study 10

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£9,000 per annum Optibelt Red Power 3 Belt Food

A bakery had six belts driving the circulation fans on their oven. Their

purpose was to achieve an improvement in energy efficiency for the

customer. When engineers inspected them, they replaced the belts with

RedPower 3, maintenance free belts. Drive power consumption was

measured before and after the replacement and an instant reduction

of 8% was recorded after the RedPower belts had been fitted. This

reduction equated to an annual cost saving of approximately £1,500 per

oven for the customer.

£10,000 Renold Stainless Steel Transmission Chain Food

A customer was facing issues with their conveyor belt which was used

to separate large potatoes from small potatoes. Large potatoes would

carry along the line and smaller ones would fall through a grate on to a

separate line. Potatoes continuously bouncing on the grate resulted in

high shock loads and the chain was being corroded from contact with a

water and chemical mixture. The customer had already trialled several

brands of stainless steel transmission chains with all showing significant

wear and corrosion within several months. Following an on-site visit by

an engineer, a trial with Renold Stainless Steel Transmission chain was

suggested. As a result, the customer experienced twice the lifetime of

the next best competitor as well as a significant improvement in machine

uptime.

Case Study 11

Case Study 12


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£4,500

£15,000

Renold Hydro-Service Chain

Renold Syno® Low Maintenance Chain

Food

Warehouse and Logistics

An ice lolly manufacturer was having trouble with the chain that drives

the freezer tunnel section of the line. Due to the demanding conditions

of regular wash downs and low temperatures, high corrosion was

witnessed on the OEM chain resulting in regular maintenance and

replacement on a six month basis.

Following an on-site assessment by an experienced engineer, Renold

Hydro-Service chain was suggested to fulfil their requirements.

Its superior corrosion resistant coating made it ideal for high wear

applications where stainless steel would not be appropriate. The

installed chain, in operation for over two years, reported no issues,

eliminated the need for regular six month maintenance and associated

production line stoppages which resulted in £4,500 cost savings.

A 24/7 distribution warehouse was using 20 elevators installed throughout

its site to transport products from one floor to another using chains with

a ‘table’ formation. Due to the proximity of the products to the chain, little

or no lubrication was allowed on the chain, resulting in uneven chain wear

which caused the tables to be unbalanced, often damaging boxes and

products. Following an on-site visit, the engineer recommended using

Renold Syno® Low Maintenance chain, which have a specially lubricated

sintered bush and are Nickel-plated to improve corrosion resistance.

After three years of use, there is still very limited wear on the chain and all

elevators continue to operate evenly with no reported issues. The project

resulted in cost savings worth £15,000.

Case Study 13

Case Study 14

National Distribution CentreHeadway RoadWolverhamptonWV10 6PZ

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www.brammer.co.uk

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delivering cost savings - brammer pt brochure march17.pdf · £11,000 timken quick-flex coupling...

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