- Customer: KRAIBURG Austria GmbH & Co. KG
- Location: Geretsberg (Austria)
- Sector: Tire industry
- Application: Rubber mix rolling mill
- Modernization of the rolling mill
- Keeping the existing production layout of the rolling mill
- Removing the outdated maintenance- and energy-intensive drive unit
- Personal consulting on current and future trends for the new drive unit
- Reliability in the entire production process
- Comprehensive customer service: Consulting and selection of the new components for the application
- Switch to an energy-efficient, low-maintenance drive
- Switch from a hydraulic drive to an electromechanical drive
- The drive solution: Customer-specific drive with the compact PHF052/T X1KP200 planetary gear unit
- Documentation and operating instructions, including declaration of incorporation
- Inverter with PROFINET
- Professional support during startup
- Modernization of the drive unit in the rolling mill to bring it up to the state of the art
- Technically coordinated drive units from a single source
- Compact solution: Direct mounting of P-X1KP on machines saves space
- Short delivery times
- Minimized downtime thanks to simple plug-in solution
- Saving on machine components such as cardan shafts and assembly frames
- Reduction of maintenance costs thanks to the components saved
- Compliance with safety requirements
- Compliance with rules and regulations
- Expert partner who is at your side from startup all the way through the entire system life cycle
Quote from Guenther Mackinger, Head of System Development at KRAIBURG Austria
Right from the initial discussions, it was clear that SEW-EURODRIVE had a high level of expertise and the commitment to creating the perfect drive for us.
Due to the new installation of a rubber mix rolling mill, we were faced with a need to procure suitable single drives. The challenge lay in transferring a relatively high torque of 105 kNm, while also having drives that are energy-efficient, space-saving, low-maintenance and at the same time low-noise. With the new drive units, we are in a position to produce our high-quality rubber mixes efficiently on a long-term basis.
Together with SEW‑EURODRIVE, we succeeded in cutting current consumption in the system significantly compared to the previous drive. Our production staff also appreciate the low noise development and compact design of the new drive units.
From the tendering phase to startup, the collaboration formed a very professional partnership. SEW-EURODRIVE will certainly be the first company KRAIBURG Austria approaches for any similar projects.
Impressions of the project
Products and solutions used
Quote from Bernhard Raudaschl, Key Account Manager at SEW-EURODRIVE Ges.m.b.H.
During the orientation phase, we worked with KRAIBURG Austria to carefully examine the manufacturing process and collaborated closely with them to create a customized solution.
To meet the customer requirements to the fullest extent, we employ an order-specific design solution – in this specific case, this involved combining the thermally optimized X1KP200 primary gear unit and the tried-and-tested PHF052/T hollow-shaft planetary gear unit. A compact water cooling circuit on a serial switch used pressure lubrication and a primary motor to ensure constant, reliable operation with high output requirements, the connection options were reduced and the cabling outlay was also minimized. At the same time, it was possible to cut noise emissions to the required levels, thus reducing maintenance intervals to a minimum. The specially adapted torque arm rounds off the complete system.
We also supported KRAIBURG Austria as a reliable partner through our service portfolio – in line with our motto of providing everything from a single source. Having successfully completed the mechanical Startup Service, we then carried out the application programming. To protect employees and comply with statutory rules and regulations, we used the functional safety technology of the SLS (Safely Limited Speed) variant of the MOVIDRIVE® B drive inverter.
The project in detail
Tires – the rubber mix makes all the difference
In general, tires are composed of:
- Natural rubber
- Synthetic rubber
- Fillers, such as silica, carbon black, carbon and chalk
- Reinforcing materials, such as steel, rayon and nylon
- Softeners, such as oils and resins
- Chemicals, such as sulfur and zinc oxide for vulcanization
- Additives from various chemicals as protection against ozone effects and damage to the material
The raw materials are mixed, then the black rubber mass is rolled and cooled, mixed again, rolled and cooled – over and over until the desired material properties are achieved. A tire can consist of more than ten rubber mixtures.
At KRAIBURG, the time had come for the roller that was key to mixing the rubber to be modernized. In addition to modernizing the drive unit, we also acted as a partner to KRAIBURG, providing our services right from the first orientation phase, through planning, engineering, procurement and delivery all the way to the ultimate startup of the system.
Goal: Modernization
Manufacturing tires is a complex process that includes numerous production steps. To continue ensuring the highest possible quality in the mixing of the rubber mass, the roller at the rubber processing company KRAIBURG needed modernizing. The KRAIBURG rubber plant commissioned SEW‑EURODRIVE to supply a drive train for the rolling mill, taking into account the need to retain the existing production layout while bringing the outdated, high-maintenance drive unit up to the state of the art and meeting the highest safety requirements.
Step 1: Orientation
To provide KRAIBURG with customized advice from the outset, we visited its premises in Geretsberg, Austria. During the decision-making process, we provided the rubber manufacturer with vital information on topics such as:
- Current and future trends: Together with KRAIBURG, we examined current and upcoming developments in the field of drive engineering for rollers in rubber manufacturing
- Rules and regulations: We worked with KRAIBURG Austria to gain an overview of the standards and legal requirements, for example from the fields of safety technology and energy efficiency. Based on this analysis, we drew up compliant solutions.
- Application expertise: We are familiar with the rubber industry and shared our many years of experience and expertise
Step 2: Planning and engineering
After we had defined the requirements together based on the existing drive, we implemented the ideas, requirements and concepts in a tailor-made drive solution for the rolling mill. With the project planning and design, we keep an eye on the safety technology and energy requirements and help select the perfect drive components. KRAIBURG opted for an order-specific design of a drive package with P-X1KP. This drive is a particularly compact and weight-optimized drive solution that is ideal for using in mixers. We also provided all technical information and CAD data.
Step 3: Procurement and delivery
After KRAIBURG Austria approved the dimension sheet in July, delivery of the customized drive unit followed just a short time laterin October. We cut the logistical outlay for the rubber manufacturer to a minimum and ensured a smooth procurement process.
Step 4: Installation and startup
We were also there for KRAIBURG with our service portfolio for the startup, ensuring the new drive technology for the rolling mill was started on time, cost-effectively and successfully . We took the entire drive technology to the plant and – taking account of the safety-related regulations – set up all parameters as required for the application, cutting the startup costs and thus preventing consequential damage.
Step 5: Operation
After startup, we continue to support KRAIBURG with our Life Cycle Services throughout the entire system life cycle of the rolling mill:
- Production support
- Remote service (remote access to diagnose the current status of the drive unit)
- Repair
- Inspection & maintenance
- Spare Parts Service
- Pick-Up and Delivery Service
- Express Assembly
- Condition Monitoring (systematic condition monitoring of the drive unit)
- 24h Service Hotline
- Energy management for optimizing the drive unit's energy efficiency
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