up-time
ENERGY EFFICIENT AND SUSTAINABLE SOLUTIONS
Up-time K aman I n d u s t r ia l Te c h n o l o g ies
page 5
page 6
page 12
FLIR i60’s new METERLiNK™ technology wirelessly captures electrical data from Extech clamp meters.
In this issue
See page 10-11.
• NEMA® Premium motors reduce energy costs while increasing reliability • Safe yet effective lubricants, cleaners and solvents made from renewable resources • Belt drive conversions prevent downtime and power spikes • Energy efficient bearings reduce power consumption and extend equipment life
Volume 10, Issue 1
page 16
page 19
A Letter From THE PRESIDENT Table of Contents ASCO Numatics
3
Baldor Electric Company
4
Walter Surface Technologies
5
Rexnord Industries, LLC
6
Krylon Products Group
7
Drives, LLC
8
Emerson Motor Technologies
9
FLIR Systems – Extech Instruments
10-11
Gates Corporation
12
RBC Bearings
13
Schaeffler Group USA
14
CRC Industries
15
Hub City Inc.
16
80/20 Inc.
17
SKF USA, Inc.
18
UltraTech International, Inc.
19
In this age of extreme competition, high energy costs and increasing environmental regulations it is important that you rely on a partner that can bring you repair and replacement solutions that not only keep your machines running but help make your plant more environmentally and operationally sustainable. At Kaman, we take this responsibility seriously. We can provide the right part, at the right time to meet your specs and we can add true value to your operation by partnering with you and recommending the right solution to meet both your long term goals and short term needs. Installing energy efficient motors to reduce utility costs, converting v-belt drives to synchronous belt drives and standardizing lubricants, cleaners and solvents to eco-grade products are just a few solutions that our salespeople can help you consider and apply. In this issue of Up-Time, we present solutions that not only deliver cost savings but more importantly add value to the long-term sustainability of your operations. Call your local Kaman representative today and let us help you determine the benefit gained in the total cost of ownership by implementing the right solution and not just the cost of a product. Regards,
T. Jack Cahill, President Kaman Industrial Technologies Corporation
2 1
- 8 0 0 - 5 2 6 - 2 6 2 6
Numatics Design Tool Reduces Compressed Air Consumption By 40% In an industrial plant, one of the largest consumers of energy is the compressed air system. Often overlooked, this is a source for significant energy savings. In most compressed air applications a pneumatic cylinder is used to move a load in one direction and a smaller load or no load in the opposite direction. The common practice is to use the same pressure for both directions. However, the pressure required for the extend stroke may be different than the pressure required for the retract stroke. The Numatics Numasizing® design tool can be used to determine the minimum required pressures for this situation. Then by applying a Numatics sandwich regulator to the circuit, set at the optimum pressures for extend and retract, significant compressed air savings can be achieved.
The example below shows potential savings of 40% for a small packaging machine with 7 actuators operating at 120 cycles per minute at 80 PSIG using Numatics Numasizing. To learn more about energy saving solutions from Numatics, contact your local Kaman representative.
Packaging Machine with 7 Actuators (Various Bore & Stroke) Original Air Consumption @ 80 PSIG (SCF/Yr)
37,317,775
Re-Designed Air Consumption Minimum Required Pressure with Safety Factor (SCF/Yr)
22,106,444
Air Saved (SCF/Yr)
15,211,331
Original Air Cost ($/Yr @ $0.35 per 1000 SCF)
$13,061
Redesigned Air Cost ($/Yr @ $0.35 per 1000 SCF)
$7,737
Air Cost Savings ($/Yr @ $0.35 per 1000 SCF)
$5,324
Numasizing is a registered trademark of Numatics, Inc.
W W W . K A M A N D I R E CT . CO M 3
Cut energy costs with Baldor•Reliance® Premium Efficient Super-E® Motors
When a foundry in Pennsylvania began an aggressive plan to cut energy costs they turned their attention to motors. They discovered that their older electric motors were consuming a sizable amount of electricity and so they began to search for an energy efficient alternative. At the same time they were also starting their 5-year program of installing dust
The new system, powered by a 500 HP Baldor•Reliance Super-E, moves air at a rate of 120,000 cfm. The return air moves through HEPA filters and heats the facility in the winter months and directs warm air outside during the summer. This project resulted in a six-figure reduction in heating costs, markedly improving comfort in the facility. To learn more contact your local Kaman representative.
collectors and wanted to standardize one motor for their entire facility. They chose Baldor•Reliance Premium Efficient Super-E motors. Baldor’s Super-E motors offer customers one of the highest levels of overall efficiencies available from any motor manufacturer, meeting or exceeding NEMA® Premium efficiency. Not only are these motors efficient, they run cooler and longer with greater reliability than other industrial motors. Baldor’s Super-E motors run cooler and last longer.
4 K A M A N
INDUSTRIAL
TECHNOLOGIES
1 - 8 0 0 - 5 2 6 - 2 6 2 6
Increase Safety, save money and Reduce Aerosol Usage with AF-WELD A large manufacturer of parts for tractors sought a weld anti-spatter that was safer for workers. They agreed to test AF-Weld, a new non-toxic, all-natural anti-spatter manufactured by Walter. All the welders unanimously preferred AF-Weld due to its ease of use and performance. The health and safety manager was satisfied because Walter’s product was completely safe. Even the foreman was happy because AF-Weld eliminated the cost of aerosol disposal. AF-Weld is an innovative anti-spatter that retracts in the presence of heat. Suitable for steel, stainless steel and aluminum, it does not cause corrosion and works equally well either wet or dry.
Each 10L bag-in-box container of AF-Weld equals 36 aerosol cans.
AF-Weld actively prevents weld porosity and cracking even when used in excess. Combined with the Air-Force aerosol refilling station, AF-Weld eliminates the need to dispose of aerosols. Save time, money and the environment with AF-Weld. Contact your local Kaman representative to learn more about the AF-Weld system.
AF-Weld actively prevents spatter even when used in excess.
W W W . K A M A N D I R E CT . CO M 5
Going Green in Beverage Production The fundamentals of green manufacturing relate to minimizing the use of resources and the environmental impact of a product. In a beverage packaging operation, this means reducing or eliminating soap and water usage while protecting container and enhancing line productivity. What’s the first step in achieving “run dry” conveyors? Start with a comprehensive survey from Rexnord of the conveyor lines in your plant so that you can clearly see the limits of each parameter of running dry. Based on the data collected, Rexnord can recommend which conveyors are candidates to run dry or which may need some form of lubrication.
Rexnord PS (Platinum Series) chain installed on this high speed PET bottle conveyor reduced the required lubrication by 2/3.
Running dry is seldom an all-or-nothing proposition. The solution maybe as simple as a conveyor chain upgrade to Platinum Series material which can operate dry at much higher speeds. Or depending on the conveyor layout, upgrade to HP™ with far less lubrication than you are using today.
6 K A M A N
INDUSTRIAL
RUN DRY – Rexnord has helped plants to run dry for over 20 years with superior, patented materials such as LF, XL, HP™ and PS®.
Examples include • A major soft drink manufacturer was able to reduce the amount of lubrication by 66% by upgrading to the Rexnord Platinum Series material • Another bottler converted to a dry lubricant and reduced plant water consumption by 675,000 gallons saving over $5000 annually in the cost of water, softener and effluent treatment, not to mention lubricant costs To find out what running dry means to your operation, contact the experts from Rexnord and Kaman for a comprehensive line review. We will determine where it’s practical and cost effective to run conveyor lines dry and where it may be best to incorporate dry lubricate technology.
Dry lubricant offers many benefits such as reduced water consumption, improved safety and clean products into the labelers or packers.
TECHNOLOGIES
1 - 8 0 0 - 5 2 6 - 2 6 2 6
Sprayon® Eco-Grade™ Lubricants and Specialty Cleaners Sprayon’s® Eco-Grade™ is a new Green Cert certified line of green lubricants and cleaning products that are safe for the environment and the health of the user. The need for high-performing and lowtoxic lubricants, cleaners and solvents in environmentally sensitive areas has been recognized and Sprayon Eco-Grade is the solution.
Eco-Grade High Performance Lube with P.T.F.E., made with renewable resources, offers excellent extreme pressure lubricity, water resistance and high temperature performance. Specifically formulated with the industrial-user and environment in mind. Eco-Grade General Purpose Lube & Penetrant, formulated with renewable resource ingredients, is a biodegradable penetrant and lube that quickly penetrates and dissolves rust, gum and corrosion. Eco-Grade Soy Degreaser is a unique soybased solvent blend that quickly penetrates and loosens a variety of industrial soils and is formulated to replace common petroleum products. Eco-Grade cleaning products offer a solution for a cleaner, healthier space to work and are safe, versatile and environmentally responsible without sacrificing performance.
Green Cert’s mission: to reduce environmental impact and to meet or exceed the most stringent regulatory requirements without sacrificing product quality.
All products on this page are Green House Gas Free and Do Not Contain Global Warming Agents.
W W W . K A M A N D I R E CT . CO M 7
The Innovative Design of Extended Life CHP® Chain Drives Efficiency
Many attempts have been made to produce roller chains capable of operating without lubrication in complex applications. Chain elongation, due to wear, is the primary mode of failure in most roller chain drives. Wear is the result of abrasion between the pin and bushing. The rate of wear between these two components is often accelerated by the operating environment or the inability to adequately provide lubricant to these parts due to product or environmental contamination.
and strength while delivering an extremely hard wear resistant pin surface. Extended Life CHP chain offers exceptional pin wear resistance and can increase wear life by 3X over conventional premium chains. Using Extended Life CHP chain is a cost effective and energy efficient way to prevent premature elongation, extend maintenance intervals and limit the need for environmentally hazardous lubricants. For more information contact your local Kaman branch.
Extended Life CHP® hard chrome plated pins possess standard steel’s metallurgical properties for toughness
8 K A M A N
INDUSTRIAL
TECHNOLOGIES
1 - 8 0 0 - 5 2 6 - 2 6 2 6
Commercial Farm Turns Green and Gains $30,000 In Energy Savings
Diesel-powered irrigation pumps have long been inefficient and a source of airborn pollutants. When commercial farmers looked for ways to reduce emissions and gain significant energy savings, they didn’t have to search farther than Emerson™ for the answer. On a recent visit to a commercial farm, Emerson and Kaman seized the opportunity to improve irrigation efficiencies, reduce air pollution and energy consumption and add a “green” element to the farm’s operation. The farm irrigated their fields using nine diesel-powered irrigation pumps. These remote, manually controlled geared units caused uneven watering, field flooding (due to pipe bursts) and high carbon emissions. Kaman and Emerson developed a new, high-efficiency electric motor powered irrigation pumping system which combines the power of a U.S. Motors®
NEMA® Premium Vertical Holloshaft® A.C. motor with a variable frequency drive and harmonic filters to achieve new levels of efficient operation and control. At an estimated savings of nearly $30,000 per pump per year, all nine diesel-powered units were converted to the new configuration. Along with on-going energy savings and reduced emissions, the farm realized a first-year payback and a healthier bottom line. Contact your local Kaman representative to schedule a field installation visit and find out how much you can save with a new high-efficiency electric pumping station. All non-Emerson Electric Co. marks shown within this document are properties of their respective owners. Emerson trademarks followed by the ® symbol are registered with the U.S. Patent and Trademark Office.
W W W . K A M A N D I R E CT . CO M 9
INCREASE EFFICIENCY AND REDUCE ENERGY USE METERLINK™-ENABLED TOOLS FROM FLIR AND EX
FLIR i60 Infrared Thermal Imager with MeterLink.
Strained budgets, prohibitive replacement costs and the need for maximum uptime can make a green manufacturing upgrade challenging to implement. Plant managers are taking the first step with MeterLink™ enabled tools from FLIR and Extech, ensuring electrical and mechanical plant assets, are optimized for maximum efficiency. Critical temperature and electrical readings are often taken together to validate efficiency upgrades, or determine if maintenance and repair is warranted. FLIR’s i60 infrared camera can diagnose overloaded motor controls or worn bearings, identify improper connections on a breaker panel or ensure a
10 K A M A N
INDUSTRIAL
building’s heating and cooling efficiency is not compromised, before energy usage skyrockets. The FLIR i60 gives professionals bestin-class infrared diagnostic capabilities to find problems faster. Fusion blends 32,400 pixel IR images with 2.3MP visual images for rich details. Built-in illuminator lamps ensure quality visual images even in dark locations. Alongside the FLIR, the Extech EX845 clamp meter is used to measure current, voltage and other electrical factors that can be essential for pinpointing inefficient operation that may cause increased energy consumption or pollution emission. The EX845 is an AC/DC clamp meter that is optimized for accurate and safe electrical readings in the industrial workplace with CATIV overvoltage protection and 1000A capacity.
TECHNOLOGIES
1 - 8 0 0 - 5 2 6 - 2 6 2 6
WITH EXTECH
EX845 also features a built-in IR thermometer.
MeterLink™ transmits EX845 clamp meter readings to a FLIR i60.
Both tools are equipped with the exclusive new MeterLink which displays and documents readings from your EX845 clamp meter directly on your FLIR infrared camera using Bluetooth wireless technology. MeterLink accelerates infrared inspections and improves accuracy by freeing thermographers from the manual process of recording additional field data.
When improving your carbon footprint is a priority, having the best tools is essential: a powerful FLIR i60 infrared camera to quickly identify hot spots plus an Extech EX845 clamp meter for detailed current and voltage readings. Having them connected is invaluable. Contact your local Kaman representative for more information. Extech EX845 1000A AC/DC Clamp Meter with MeterLink™.
W W W . K A M A N D I R E CT . CO M 11
Drive conversions save $500K and counting A manufacturer in the food packaging industry was looking for a solution to reduce energy expenses and eliminate the enormous power spikes the plant was experiencing.
Gates surveyed the facility’s more than 150 drives and recommended they convert to Poly Chain® GT® Carbon®. The Poly Chain GT Carbon belt drive system delivers 5% or more in energy savings compared to slipping v-belt drives which are prone to power spikes. The Poly Chain belt has a polyurethane construction and unique jacket that are resistant to chemicals, wash down and abrasion. It also uses a carbon tensile cord so there is no stretch, providing stable performance and long life. To date 1/3 of the drives have been converted to Poly Chain GT Carbon belt drives with the following results: • Energy savings was gained as inefficient v-belt drives were converted • Unscheduled downtime was virtually eliminated • Power spikes are no more
Poly Chain® GT® Carbon® belt drive systems deliver stable energy usage and eliminate costly power spikes.
The facility’s reliability engineer was looking for a solution that would meet these requirements:
• Current conversions have already delivered over $550,000 in savings Contact your Kaman representative today to learn how Kaman and Gates can help your facility be more energy efficient.
• Gain energy savings • Reduce maintenance costs • Prevent downtime • Reduce power spikes
12 K A M A N
INDUSTRIAL
TECHNOLOGIES
1 - 8 0 0 - 5 2 6 - 2 6 2 6
RBC Roller® – A Superior Alternative for the environment
The RBC Roller® cam follower is available in sizes ranging from 1"-10".
A key supplier to truck manufacturers was using needle bearing cam followers for the rail guides on their 11ft gates, but they were experiencing a high number of warranty claims. Bearings were failing, in part, due to infrequent lubrication, corrosion and contamination. When cam followers are re-greased, the internal grease is purged out of the cam follower and ends up on the equipment or ground contaminating the environment.
The RBC Roller® cam follower is lubed for life and does not need re-greasing. This helped eliminate the need for costly machine maintenance downtime and cleanup. In addition, the superior seals on the RBC Roller reduce the effects of corrosion and contamination from extreme weather, dirt and grit. Using RBC Roller cam followers allowed the supplier to reduce their costs, downtime and environmental impact. To learn more, contact your local Kaman branch.
W W W . K A M A N D I R E CT . CO M 13
LOWER RUNNING FRICTION MEANS LOWER ENERGY USE All products belonging to the X-life family feature enhanced characteristics including: • Increased load carrying capacity • Longer life • Lower operating temperature • Reduced noise levels • Lower maintenance Welcome to the future! Unmatched engineering excellence from INA, FAG & Barden brand bearings. Our X-life quality bearings offer improved roller geometry and raceway surface finish. This means our bearings reduce the friction in your equipment resulting in improved operational efficiencies. The cooler running, smoother rolling and less vibration results in longer service life and reduced energy consumption.
The bottom line is, X-life improves machine performance reducing downtime and energy use. Contact your local Kaman branch for more information.
X-life bearings reduce friction and increase service life.
14 K A M A N
INDUSTRIAL
TECHNOLOGIES
1 - 8 0 0 - 5 2 6 - 2 6 2 6
Helping green the workplace environment Looking for a green certified, environmentally preferred cleaner that performs as well as traditional water-based cleaners? Well, look no more! CRC’s Green Force™ product line is formulated to meet strict environmental requirements without sacrificing performance. • U.S. EPA Design for Environment (DfE) recognized • Low VOC content • Biodegradable • Not classified as a Hazardous Waste
Green Force™ Heavy Duty Cleaner • Quickly removes petroleum based soils such as grease, grime and oil found in manufacturing and warehouse environments • Concentrated formulas available in 1 gallon (#14455), 5 gallon (#14456) and 55 gallon (#14458) sizes
• Non-flammable
Green Force™ Glass & Surface Cleaner • Effectively cuts greasy films and soils leaving glass and other hard surfaces sparkling clean
Green Force™ Multi-Purpose Cleaner • Effectively cuts greasy films and soils leaving surfaces sparkling clean
• Ready to use formula available in 32 oz. spray bottle (#14460) and concentrated formula available in 1 gallon (#14461) sizes
• Concentrated formulas available in 1 gallon (#14450), 5 gallon (#14451) and 55 gallon (#14452) sizes
For these and other green solutions to your everyday workplace needs, contact your local Kaman representative.
• Does not contain Nonyl Phenols • Does not contain Phosphates • Low odor
®
W W W . K A M A N D I R E CT . CO M 15
90% efficiency and 2X more torque, in a no-hassle worm drive replacement Low efficiency is an inherent property of worm gear technology. Hub City’s new HERA (High Efficiency Right Angle) gearbox brings high-efficiency performance and increased torque capacity together in a “worm gear” package.
This drop-in alternative provides a green option for millions of installed worm speed reducers. Efficiency 90% efficiency for all ratios, allows • Up to 40% energy savings • Rapid payback of initial cost • Smaller motor requirements (less wasted energy) Torque Density Up to 2X more torque capacity, permits • Longer gearbox life • Increased uptime • Gearbox downsizing Worm Drive Interchange Size consolidation and modular versatility, provides
Hub City HERA Gearbox (Patent Pending).
• Bolt-in replacement of most standard worm gear drives • Reduced inventory Operating Cost Example
HERA45
3.25" Worm Usable Energy
Wasted Energy
*Hera45 vs. 3.25" Worm, 2,600 in-lbs, 60/1 ratio, 24/5 duty cycle, $0.10/kW-hr.
16 K A M A N
INDUSTRIAL
TECHNOLOGIES
1 - 8 0 0 - 5 2 6 - 2 6 2 6
stop welding. stop painting. Start building.
Welded frames add time and cost to projects while increasing your carbon footprint.
Modular framing systems – a sustainable, recyclable solution.
80/20 provides modular framing systems that can adjust to fit any industry and
Benefits of using 80/20’s T-slotted aluminum frames
application. From light to heavy-duty,
• Versatility
80/20 modular framing provides a secure
• Sustainability
and OSHA-approved guard, display,
• Non-toxic
workstation or just about any other
• Strong, yet lightweight
application you can imagine.
• 95% recyclable
95% recyclable T-slotted aluminum offers many advantages over welded steel. The material is strong, lightweight, easy to machine and involves less engineering time and assembly tools than welded steel. Aluminum is also cost-effective and can be quickly and easily reconfigured for design changes. Aluminum can act as a pressure manifold for air tools, C-Frame presses, drilling fixtures, router guides and much more.
• Saves time and money over welded steel
• No paint fumes • No welding fumes Eliminate projects that sap your space and increase your carbon footprint. Turn to 80/20 today and build something that lasts long. Contact your Kaman representative today to schedule an appointment to learn more.
W W W . K A M A N D I R E CT . CO M 17
Introducing new SKF Energy Efficient (E2) bearings It’s a small thing – replacing the conventional bearings in equipment with
Power loss (watt) 15
new SKF Energy Efficient (E2) bearings. But in the long run, it can make a 10
big difference. Because in low-to-normal load applications such as electric motors, pumps and conveyors, SKF Energy Efficient deep groove ball bearings consume 30 to 50% less energy. In many cases they can run cooler at equivalent loads and speeds, reducing lubricant use and, potentially, extending the life of components and the equipment itself. But E2 bearings aren’t just good for your business, they’re good for your planet. In fact, if used on every industrial motor in the US and EU, potential energy savings would equal 2.46 billion kWh/year.
5
t-50% t-30%
0
0
2 000
4 000
6 000
8 000
Rotational speed (r/min) Standard SKF bearing SKF Energy Efficient bearing
6306 size shielded bearing radial load: 0,75 kN Temperature: 80° C
Difference in power loss
Power loss simulation results showing energy savings of SKF Energy Efficient deep groove ball bearings compared to standard SKF bearings. Energy savings compared to other manufacturers’ bearings can be even more dramatic.
Ask your Kaman sales representative for more information about the benefits of SKF E2 bearings.
18 K A M A N
INDUSTRIAL
TECHNOLOGIES
1 - 8 0 0 - 5 2 6 - 2 6 2 6
SECONDARY SPILL CONTAINMENT SOLUTIONS save $20,000 in regulatory fines A large manufacturer of industrial components approached UltraTech regarding environmental concerns related to the storage of petroleum products at their manufacturing facility. The manufacturer was facing fines in excess of $20,000 due to various EPA violations. Specifically, there were a number of 55 gallon drums and 275 gallon IBC tanks that held oil/hydraulic fluid that were in need of secondary containment. Also, it was found that hazardous fluids were entering the surrounding storm basins on the property. After surveying the site, UltraTech recommended that all storm drains be outfitted with Ultra-Drainguards, (made from 100% recycled content) in order to catch hydrocarbons as well as sediment/debris. All 55 gallon tanks and 275 gallon totes were to be stored in
Ultra-Hard Top Plus containment units in order to capture any spills/leaks and to protect the containers from storm events. Indoors, all 55-gallon drums were to be placed on Ultra-P2/P4 Spill Pallets plus Ultra-Funnels were to be used to prevent accidental spills. The manufacturer complied with these recommendations and avoided regulatory fines while implementing a long-term, environmentally friendly solution. To schedule a survey of your secondary spill containment needs, contact your local Kaman representative.
W W W . K A M A N D I R E CT . CO M 19
B ear i n gs
The Branch Nearest You…
Energy Management Assistance Kaman can assist you to develop a sustainable energy management program that will drive profits to your bottom line. Contact your local Kaman representative to find out how Kaman can help put its energy management expertise to work for you.
Kaman NEWS
Ask how Kaman can help you be EISA compliant.
are you ready for eisa 2010?
White Drive is the world’s largest independent manufacturer of low speed high torque hydraulics motors. Complimentary products include brakes, flow dividers, variable displacement piston pumps and accessories.
New Product Lines • White Drive Products, Inc.
1 Waterside Crossing Windsor, CT 06095
Crown is a pioneer of matting products for industrial, ergonomic and entrance areas. Crown carries a wide selection of industrial mats for dry, wet and wet/oily areas to help prevent slips, trips and falls.
• Crown Mats and Matting
lines of secondary spill containment and spill response products on the market today. UltraTech products are designed to meet a variety of environmental regulations.
Fluid P o w er MRO S upplies
• UltraTech International, Inc. UltraTech offers one of the most innovative
P ow er T ran smissi on Elec trical Mat erial H andling Mo tion C on trol
Item #: 70317 (04/10)
Up-time K aman I n d u s t r ia l Te c h n o l o g ies
page 5
page 6
page 12
FLIR i60’s new METERLiNK™ technology wirelessly captures electrical data from Extech clamp meters.
In this issue
See page 10-11.
• NEMA® Premium motors reduce energy costs while increasing reliability • Safe yet effective lubricants, cleaners and solvents made from renewable resources • Belt drive conversions prevent downtime and power spikes • Energy efficient bearings reduce power consumption and extend equipment life
Volume 10, Issue 1
page 16
page 19
A Letter From THE PRESIDENT Table of Contents ASCO Numatics
3
Baldor Electric Company
4
Walter Surface Technologies
5
Rexnord Industries, LLC
6
Krylon Products Group
7
Drives, LLC
8
Emerson Motor Technologies
9
FLIR Systems – Extech Instruments
10-11
Gates Corporation
12
RBC Bearings
13
Schaeffler Group USA
14
CRC Industries
15
Hub City Inc.
16
80/20 Inc.
17
SKF USA, Inc.
18
UltraTech International, Inc.
19
In this age of extreme competition, high energy costs and increasing environmental regulations it is important that you rely on a partner that can bring you repair and replacement solutions that not only keep your machines running but help make your plant more environmentally and operationally sustainable. At Kaman, we take this responsibility seriously. We can provide the right part, at the right time to meet your specs and we can add true value to your operation by partnering with you and recommending the right solution to meet both your long term goals and short term needs. Installing energy efficient motors to reduce utility costs, converting v-belt drives to synchronous belt drives and standardizing lubricants, cleaners and solvents to eco-grade products are just a few solutions that our salespeople can help you consider and apply. In this issue of Up-Time, we present solutions that not only deliver cost savings but more importantly add value to the long-term sustainability of your operations. Call your local Kaman representative today and let us help you determine the benefit gained in the total cost of ownership by implementing the right solution and not just the cost of a product. Regards,
T. Jack Cahill, President Kaman Industrial Technologies Corporation
2 1
- 8 0 0 - 5 2 6 - 2 6 2 6
Numatics Design Tool Reduces Compressed Air Consumption By 40% In an industrial plant, one of the largest consumers of energy is the compressed air system. Often overlooked, this is a source for significant energy savings. In most compressed air applications a pneumatic cylinder is used to move a load in one direction and a smaller load or no load in the opposite direction. The common practice is to use the same pressure for both directions. However, the pressure required for the extend stroke may be different than the pressure required for the retract stroke. The Numatics Numasizing® design tool can be used to determine the minimum required pressures for this situation. Then by applying a Numatics sandwich regulator to the circuit, set at the optimum pressures for extend and retract, significant compressed air savings can be achieved.
The example below shows potential savings of 40% for a small packaging machine with 7 actuators operating at 120 cycles per minute at 80 PSIG using Numatics Numasizing. To learn more about energy saving solutions from Numatics, contact your local Kaman representative.
Packaging Machine with 7 Actuators (Various Bore & Stroke) Original Air Consumption @ 80 PSIG (SCF/Yr)
37,317,775
Re-Designed Air Consumption Minimum Required Pressure with Safety Factor (SCF/Yr)
22,106,444
Air Saved (SCF/Yr)
15,211,331
Original Air Cost ($/Yr @ $0.35 per 1000 SCF)
$13,061
Redesigned Air Cost ($/Yr @ $0.35 per 1000 SCF)
$7,737
Air Cost Savings ($/Yr @ $0.35 per 1000 SCF)
$5,324
Numasizing is a registered trademark of Numatics, Inc.
W W W . K A M A N D I R E CT . CO M 3
Cut energy costs with Baldor•Reliance® Premium Efficient Super-E® Motors
When a foundry in Pennsylvania began an aggressive plan to cut energy costs they turned their attention to motors. They discovered that their older electric motors were consuming a sizable amount of electricity and so they began to search for an energy efficient alternative. At the same time they were also starting their 5-year program of installing dust
The new system, powered by a 500 HP Baldor•Reliance Super-E, moves air at a rate of 120,000 cfm. The return air moves through HEPA filters and heats the facility in the winter months and directs warm air outside during the summer. This project resulted in a six-figure reduction in heating costs, markedly improving comfort in the facility. To learn more contact your local Kaman representative.
collectors and wanted to standardize one motor for their entire facility. They chose Baldor•Reliance Premium Efficient Super-E motors. Baldor’s Super-E motors offer customers one of the highest levels of overall efficiencies available from any motor manufacturer, meeting or exceeding NEMA® Premium efficiency. Not only are these motors efficient, they run cooler and longer with greater reliability than other industrial motors. Baldor’s Super-E motors run cooler and last longer.
4 K A M A N
INDUSTRIAL
TECHNOLOGIES
1 - 8 0 0 - 5 2 6 - 2 6 2 6
Increase Safety, save money and Reduce Aerosol Usage with AF-WELD A large manufacturer of parts for tractors sought a weld anti-spatter that was safer for workers. They agreed to test AF-Weld, a new non-toxic, all-natural anti-spatter manufactured by Walter. All the welders unanimously preferred AF-Weld due to its ease of use and performance. The health and safety manager was satisfied because Walter’s product was completely safe. Even the foreman was happy because AF-Weld eliminated the cost of aerosol disposal. AF-Weld is an innovative anti-spatter that retracts in the presence of heat. Suitable for steel, stainless steel and aluminum, it does not cause corrosion and works equally well either wet or dry.
Each 10L bag-in-box container of AF-Weld equals 36 aerosol cans.
AF-Weld actively prevents weld porosity and cracking even when used in excess. Combined with the Air-Force aerosol refilling station, AF-Weld eliminates the need to dispose of aerosols. Save time, money and the environment with AF-Weld. Contact your local Kaman representative to learn more about the AF-Weld system.
AF-Weld actively prevents spatter even when used in excess.
W W W . K A M A N D I R E CT . CO M 5
Going Green in Beverage Production The fundamentals of green manufacturing relate to minimizing the use of resources and the environmental impact of a product. In a beverage packaging operation, this means reducing or eliminating soap and water usage while protecting container and enhancing line productivity. What’s the first step in achieving “run dry” conveyors? Start with a comprehensive survey from Rexnord of the conveyor lines in your plant so that you can clearly see the limits of each parameter of running dry. Based on the data collected, Rexnord can recommend which conveyors are candidates to run dry or which may need some form of lubrication.
Rexnord PS (Platinum Series) chain installed on this high speed PET bottle conveyor reduced the required lubrication by 2/3.
Running dry is seldom an all-or-nothing proposition. The solution maybe as simple as a conveyor chain upgrade to Platinum Series material which can operate dry at much higher speeds. Or depending on the conveyor layout, upgrade to HP™ with far less lubrication than you are using today.
6 K A M A N
INDUSTRIAL
RUN DRY – Rexnord has helped plants to run dry for over 20 years with superior, patented materials such as LF, XL, HP™ and PS®.
Examples include • A major soft drink manufacturer was able to reduce the amount of lubrication by 66% by upgrading to the Rexnord Platinum Series material • Another bottler converted to a dry lubricant and reduced plant water consumption by 675,000 gallons saving over $5000 annually in the cost of water, softener and effluent treatment, not to mention lubricant costs To find out what running dry means to your operation, contact the experts from Rexnord and Kaman for a comprehensive line review. We will determine where it’s practical and cost effective to run conveyor lines dry and where it may be best to incorporate dry lubricate technology.
Dry lubricant offers many benefits such as reduced water consumption, improved safety and clean products into the labelers or packers.
TECHNOLOGIES
1 - 8 0 0 - 5 2 6 - 2 6 2 6
Sprayon® Eco-Grade™ Lubricants and Specialty Cleaners Sprayon’s® Eco-Grade™ is a new Green Cert certified line of green lubricants and cleaning products that are safe for the environment and the health of the user. The need for high-performing and lowtoxic lubricants, cleaners and solvents in environmentally sensitive areas has been recognized and Sprayon Eco-Grade is the solution.
Eco-Grade High Performance Lube with P.T.F.E., made with renewable resources, offers excellent extreme pressure lubricity, water resistance and high temperature performance. Specifically formulated with the industrial-user and environment in mind. Eco-Grade General Purpose Lube & Penetrant, formulated with renewable resource ingredients, is a biodegradable penetrant and lube that quickly penetrates and dissolves rust, gum and corrosion. Eco-Grade Soy Degreaser is a unique soybased solvent blend that quickly penetrates and loosens a variety of industrial soils and is formulated to replace common petroleum products. Eco-Grade cleaning products offer a solution for a cleaner, healthier space to work and are safe, versatile and environmentally responsible without sacrificing performance.
Green Cert’s mission: to reduce environmental impact and to meet or exceed the most stringent regulatory requirements without sacrificing product quality.
All products on this page are Green House Gas Free and Do Not Contain Global Warming Agents.
W W W . K A M A N D I R E CT . CO M 7
The Innovative Design of Extended Life CHP® Chain Drives Efficiency
Many attempts have been made to produce roller chains capable of operating without lubrication in complex applications. Chain elongation, due to wear, is the primary mode of failure in most roller chain drives. Wear is the result of abrasion between the pin and bushing. The rate of wear between these two components is often accelerated by the operating environment or the inability to adequately provide lubricant to these parts due to product or environmental contamination.
and strength while delivering an extremely hard wear resistant pin surface. Extended Life CHP chain offers exceptional pin wear resistance and can increase wear life by 3X over conventional premium chains. Using Extended Life CHP chain is a cost effective and energy efficient way to prevent premature elongation, extend maintenance intervals and limit the need for environmentally hazardous lubricants. For more information contact your local Kaman branch.
Extended Life CHP® hard chrome plated pins possess standard steel’s metallurgical properties for toughness
8 K A M A N
INDUSTRIAL
TECHNOLOGIES
1 - 8 0 0 - 5 2 6 - 2 6 2 6
Commercial Farm Turns Green and Gains $30,000 In Energy Savings
Diesel-powered irrigation pumps have long been inefficient and a source of airborn pollutants. When commercial farmers looked for ways to reduce emissions and gain significant energy savings, they didn’t have to search farther than Emerson™ for the answer. On a recent visit to a commercial farm, Emerson and Kaman seized the opportunity to improve irrigation efficiencies, reduce air pollution and energy consumption and add a “green” element to the farm’s operation. The farm irrigated their fields using nine diesel-powered irrigation pumps. These remote, manually controlled geared units caused uneven watering, field flooding (due to pipe bursts) and high carbon emissions. Kaman and Emerson developed a new, high-efficiency electric motor powered irrigation pumping system which combines the power of a U.S. Motors®
NEMA® Premium Vertical Holloshaft® A.C. motor with a variable frequency drive and harmonic filters to achieve new levels of efficient operation and control. At an estimated savings of nearly $30,000 per pump per year, all nine diesel-powered units were converted to the new configuration. Along with on-going energy savings and reduced emissions, the farm realized a first-year payback and a healthier bottom line. Contact your local Kaman representative to schedule a field installation visit and find out how much you can save with a new high-efficiency electric pumping station. All non-Emerson Electric Co. marks shown within this document are properties of their respective owners. Emerson trademarks followed by the ® symbol are registered with the U.S. Patent and Trademark Office.
W W W . K A M A N D I R E CT . CO M 9
INCREASE EFFICIENCY AND REDUCE ENERGY USE METERLINK™-ENABLED TOOLS FROM FLIR AND EX
FLIR i60 Infrared Thermal Imager with MeterLink.
Strained budgets, prohibitive replacement costs and the need for maximum uptime can make a green manufacturing upgrade challenging to implement. Plant managers are taking the first step with MeterLink™ enabled tools from FLIR and Extech, ensuring electrical and mechanical plant assets, are optimized for maximum efficiency. Critical temperature and electrical readings are often taken together to validate efficiency upgrades, or determine if maintenance and repair is warranted. FLIR’s i60 infrared camera can diagnose overloaded motor controls or worn bearings, identify improper connections on a breaker panel or ensure a
10 K A M A N
INDUSTRIAL
building’s heating and cooling efficiency is not compromised, before energy usage skyrockets. The FLIR i60 gives professionals bestin-class infrared diagnostic capabilities to find problems faster. Fusion blends 32,400 pixel IR images with 2.3MP visual images for rich details. Built-in illuminator lamps ensure quality visual images even in dark locations. Alongside the FLIR, the Extech EX845 clamp meter is used to measure current, voltage and other electrical factors that can be essential for pinpointing inefficient operation that may cause increased energy consumption or pollution emission. The EX845 is an AC/DC clamp meter that is optimized for accurate and safe electrical readings in the industrial workplace with CATIV overvoltage protection and 1000A capacity.
TECHNOLOGIES
1 - 8 0 0 - 5 2 6 - 2 6 2 6
WITH EXTECH
EX845 also features a built-in IR thermometer.
MeterLink™ transmits EX845 clamp meter readings to a FLIR i60.
Both tools are equipped with the exclusive new MeterLink which displays and documents readings from your EX845 clamp meter directly on your FLIR infrared camera using Bluetooth wireless technology. MeterLink accelerates infrared inspections and improves accuracy by freeing thermographers from the manual process of recording additional field data.
When improving your carbon footprint is a priority, having the best tools is essential: a powerful FLIR i60 infrared camera to quickly identify hot spots plus an Extech EX845 clamp meter for detailed current and voltage readings. Having them connected is invaluable. Contact your local Kaman representative for more information. Extech EX845 1000A AC/DC Clamp Meter with MeterLink™.
W W W . K A M A N D I R E CT . CO M 11
Drive conversions save $500K and counting A manufacturer in the food packaging industry was looking for a solution to reduce energy expenses and eliminate the enormous power spikes the plant was experiencing.
Gates surveyed the facility’s more than 150 drives and recommended they convert to Poly Chain® GT® Carbon®. The Poly Chain GT Carbon belt drive system delivers 5% or more in energy savings compared to slipping v-belt drives which are prone to power spikes. The Poly Chain belt has a polyurethane construction and unique jacket that are resistant to chemicals, wash down and abrasion. It also uses a carbon tensile cord so there is no stretch, providing stable performance and long life. To date 1/3 of the drives have been converted to Poly Chain GT Carbon belt drives with the following results: • Energy savings was gained as inefficient v-belt drives were converted • Unscheduled downtime was virtually eliminated • Power spikes are no more
Poly Chain® GT® Carbon® belt drive systems deliver stable energy usage and eliminate costly power spikes.
The facility’s reliability engineer was looking for a solution that would meet these requirements:
• Current conversions have already delivered over $550,000 in savings Contact your Kaman representative today to learn how Kaman and Gates can help your facility be more energy efficient.
• Gain energy savings • Reduce maintenance costs • Prevent downtime • Reduce power spikes
12 K A M A N
INDUSTRIAL
TECHNOLOGIES
1 - 8 0 0 - 5 2 6 - 2 6 2 6
RBC Roller® – A Superior Alternative for the environment
The RBC Roller® cam follower is available in sizes ranging from 1"-10".
A key supplier to truck manufacturers was using needle bearing cam followers for the rail guides on their 11ft gates, but they were experiencing a high number of warranty claims. Bearings were failing, in part, due to infrequent lubrication, corrosion and contamination. When cam followers are re-greased, the internal grease is purged out of the cam follower and ends up on the equipment or ground contaminating the environment.
The RBC Roller® cam follower is lubed for life and does not need re-greasing. This helped eliminate the need for costly machine maintenance downtime and cleanup. In addition, the superior seals on the RBC Roller reduce the effects of corrosion and contamination from extreme weather, dirt and grit. Using RBC Roller cam followers allowed the supplier to reduce their costs, downtime and environmental impact. To learn more, contact your local Kaman branch.
W W W . K A M A N D I R E CT . CO M 13
LOWER RUNNING FRICTION MEANS LOWER ENERGY USE All products belonging to the X-life family feature enhanced characteristics including: • Increased load carrying capacity • Longer life • Lower operating temperature • Reduced noise levels • Lower maintenance Welcome to the future! Unmatched engineering excellence from INA, FAG & Barden brand bearings. Our X-life quality bearings offer improved roller geometry and raceway surface finish. This means our bearings reduce the friction in your equipment resulting in improved operational efficiencies. The cooler running, smoother rolling and less vibration results in longer service life and reduced energy consumption.
The bottom line is, X-life improves machine performance reducing downtime and energy use. Contact your local Kaman branch for more information.
X-life bearings reduce friction and increase service life.
14 K A M A N
INDUSTRIAL
TECHNOLOGIES
1 - 8 0 0 - 5 2 6 - 2 6 2 6
Helping green the workplace environment Looking for a green certified, environmentally preferred cleaner that performs as well as traditional water-based cleaners? Well, look no more! CRC’s Green Force™ product line is formulated to meet strict environmental requirements without sacrificing performance. • U.S. EPA Design for Environment (DfE) recognized • Low VOC content • Biodegradable • Not classified as a Hazardous Waste
Green Force™ Heavy Duty Cleaner • Quickly removes petroleum based soils such as grease, grime and oil found in manufacturing and warehouse environments • Concentrated formulas available in 1 gallon (#14455), 5 gallon (#14456) and 55 gallon (#14458) sizes
• Non-flammable
Green Force™ Glass & Surface Cleaner • Effectively cuts greasy films and soils leaving glass and other hard surfaces sparkling clean
Green Force™ Multi-Purpose Cleaner • Effectively cuts greasy films and soils leaving surfaces sparkling clean
• Ready to use formula available in 32 oz. spray bottle (#14460) and concentrated formula available in 1 gallon (#14461) sizes
• Concentrated formulas available in 1 gallon (#14450), 5 gallon (#14451) and 55 gallon (#14452) sizes
For these and other green solutions to your everyday workplace needs, contact your local Kaman representative.
• Does not contain Nonyl Phenols • Does not contain Phosphates • Low odor
®
W W W . K A M A N D I R E CT . CO M 15
90% efficiency and 2X more torque, in a no-hassle worm drive replacement Low efficiency is an inherent property of worm gear technology. Hub City’s new HERA (High Efficiency Right Angle) gearbox brings high-efficiency performance and increased torque capacity together in a “worm gear” package.
This drop-in alternative provides a green option for millions of installed worm speed reducers. Efficiency 90% efficiency for all ratios, allows • Up to 40% energy savings • Rapid payback of initial cost • Smaller motor requirements (less wasted energy) Torque Density Up to 2X more torque capacity, permits • Longer gearbox life • Increased uptime • Gearbox downsizing Worm Drive Interchange Size consolidation and modular versatility, provides
Hub City HERA Gearbox (Patent Pending).
• Bolt-in replacement of most standard worm gear drives • Reduced inventory Operating Cost Example
HERA45
3.25" Worm Usable Energy
Wasted Energy
*Hera45 vs. 3.25" Worm, 2,600 in-lbs, 60/1 ratio, 24/5 duty cycle, $0.10/kW-hr.
16 K A M A N
INDUSTRIAL
TECHNOLOGIES
1 - 8 0 0 - 5 2 6 - 2 6 2 6
stop welding. stop painting. Start building.
Welded frames add time and cost to projects while increasing your carbon footprint.
Modular framing systems – a sustainable, recyclable solution.
80/20 provides modular framing systems that can adjust to fit any industry and
Benefits of using 80/20’s T-slotted aluminum frames
application. From light to heavy-duty,
• Versatility
80/20 modular framing provides a secure
• Sustainability
and OSHA-approved guard, display,
• Non-toxic
workstation or just about any other
• Strong, yet lightweight
application you can imagine.
• 95% recyclable
95% recyclable T-slotted aluminum offers many advantages over welded steel. The material is strong, lightweight, easy to machine and involves less engineering time and assembly tools than welded steel. Aluminum is also cost-effective and can be quickly and easily reconfigured for design changes. Aluminum can act as a pressure manifold for air tools, C-Frame presses, drilling fixtures, router guides and much more.
• Saves time and money over welded steel
• No paint fumes • No welding fumes Eliminate projects that sap your space and increase your carbon footprint. Turn to 80/20 today and build something that lasts long. Contact your Kaman representative today to schedule an appointment to learn more.
W W W . K A M A N D I R E CT . CO M 17
Introducing new SKF Energy Efficient (E2) bearings It’s a small thing – replacing the conventional bearings in equipment with
Power loss (watt) 15
new SKF Energy Efficient (E2) bearings. But in the long run, it can make a 10
big difference. Because in low-to-normal load applications such as electric motors, pumps and conveyors, SKF Energy Efficient deep groove ball bearings consume 30 to 50% less energy. In many cases they can run cooler at equivalent loads and speeds, reducing lubricant use and, potentially, extending the life of components and the equipment itself. But E2 bearings aren’t just good for your business, they’re good for your planet. In fact, if used on every industrial motor in the US and EU, potential energy savings would equal 2.46 billion kWh/year.
5
t-50% t-30%
0
0
2 000
4 000
6 000
8 000
Rotational speed (r/min) Standard SKF bearing SKF Energy Efficient bearing
6306 size shielded bearing radial load: 0,75 kN Temperature: 80° C
Difference in power loss
Power loss simulation results showing energy savings of SKF Energy Efficient deep groove ball bearings compared to standard SKF bearings. Energy savings compared to other manufacturers’ bearings can be even more dramatic.
Ask your Kaman sales representative for more information about the benefits of SKF E2 bearings.
18 K A M A N
INDUSTRIAL
TECHNOLOGIES
1 - 8 0 0 - 5 2 6 - 2 6 2 6
SECONDARY SPILL CONTAINMENT SOLUTIONS save $20,000 in regulatory fines A large manufacturer of industrial components approached UltraTech regarding environmental concerns related to the storage of petroleum products at their manufacturing facility. The manufacturer was facing fines in excess of $20,000 due to various EPA violations. Specifically, there were a number of 55 gallon drums and 275 gallon IBC tanks that held oil/hydraulic fluid that were in need of secondary containment. Also, it was found that hazardous fluids were entering the surrounding storm basins on the property. After surveying the site, UltraTech recommended that all storm drains be outfitted with Ultra-Drainguards, (made from 100% recycled content) in order to catch hydrocarbons as well as sediment/debris. All 55 gallon tanks and 275 gallon totes were to be stored in
Ultra-Hard Top Plus containment units in order to capture any spills/leaks and to protect the containers from storm events. Indoors, all 55-gallon drums were to be placed on Ultra-P2/P4 Spill Pallets plus Ultra-Funnels were to be used to prevent accidental spills. The manufacturer complied with these recommendations and avoided regulatory fines while implementing a long-term, environmentally friendly solution. To schedule a survey of your secondary spill containment needs, contact your local Kaman representative.
W W W . K A M A N D I R E CT . CO M 19
B ear i n gs
The Branch Nearest You…
Energy Management Assistance Kaman can assist you to develop a sustainable energy management program that will drive profits to your bottom line. Contact your local Kaman representative to find out how Kaman can help put its energy management expertise to work for you.
Kaman NEWS
Ask how Kaman can help you be EISA compliant.
are you ready for eisa 2010?
White Drive is the world’s largest independent manufacturer of low speed high torque hydraulics motors. Complimentary products include brakes, flow dividers, variable displacement piston pumps and accessories.
New Product Lines • White Drive Products, Inc.
1 Waterside Crossing Windsor, CT 06095
Crown is a pioneer of matting products for industrial, ergonomic and entrance areas. Crown carries a wide selection of industrial mats for dry, wet and wet/oily areas to help prevent slips, trips and falls.
• Crown Mats and Matting
lines of secondary spill containment and spill response products on the market today. UltraTech products are designed to meet a variety of environmental regulations.
Fluid P o w er MRO S upplies
• UltraTech International, Inc. UltraTech offers one of the most innovative
P ow er T ran smissi on Elec trical Mat erial H andling Mo tion C on trol
Item #: 70317 (04/10)
