Retrofitting existing intralogistics systems can provide several advantages over completely replacing them. It typically involves lower operational and capital costs compared to installing new equipment. Additionally, the risk of failure is significantly reduced when retrofitting, which ensures a smoother transition with little to no downtime when implementing a new system. The retrofitting process can be completed quickly and with minimal disruption to operations. It also allows for modifications tailored to your specific application needs, offering greater flexibility and customization. Moreover, retrofitting can significantly reduce your operation and maintenance costs by addressing issues related to friction and wear in older systems.
Upgrading to a modern conveyor system can significantly enhance productivity and efficiency by reducing downtime and increasing capacity. This not only prolongs the life of the existing conveyor but also decreases the chances of premature replacement. Retrofitting can introduce various safety features and improvements, such as lower noise levels, better lighting, and enhanced ergonomics. It also allows for integration with new technologies, including automation and control systems, which can further improve performance. Most importantly, retrofitting prepares a conveyor system for future technological advancements, ensuring it remains competitive and efficient.
Here are some specifics regarding retrofitting:
- Replacing old, worn-out belts with new ones
- Upgrading to zero-pressure accumulation (ZPA) or other advanced conveyor technologies
- Integrating automation and control systems to improve efficiency and reduce labor costs
- Replacing mechanical components with more reliable and efficient electric or pneumatic systems
- Improving lighting and ergonomics to enhance worker safety and comfort
Dangers and risks of not upgrading
Upgrading to a modern conveyor system can significantly enhance productivity and efficiency by reducing downtime and increasing system capacity. This not only extends the life of the existing conveyor but also decreases the likelihood of premature replacement. Retrofitting a conveyor system can introduce essential safety features and improvements, such as lower noise levels, better lighting, and enhanced ergonomics. It also allows for integration with new technologies, including automation and control systems, which can further boost performance. Most importantly, retrofitting prepares the conveyor system for future technological advancements, ensuring that it remains competitive and efficient.
Conveyor degradation often occurs due to inadequate maintenance, which includes neglecting routine inspections, cleaning, and lubrication. This negligence can lead to premature wear and breakdowns. Moreover, improper design or installation can cause operational issues and failures, resulting in accidents and injuries, as well as potentially costly workers’ compensation claims and legal liabilities. Conveyors that are not designed for the specific products being handled can also cause damage or degradation, leading to inferior products and quality control problems.
Extreme temperatures, high humidity, and exposure to chemicals can adversely affect the performance of the belt and its components. Overloading or exceeding the conveyor’s capacity can result in belt slippage, damage, and increased downtime. Failing to upgrade conveyors leads to reduced capacity, resulting in decreased production rates, inefficient resource usage, and higher maintenance costs. This oversight can limit a business’s ability to scale and meet rising demand, potentially resulting in lost revenue and market share. Additionally, neglecting upgrades can create compliance issues, which may lead to fines or penalties.
Older conveyors typically require frequent repairs and replacements, contributing to higher maintenance costs and potential downtime. They often consume more energy than newer, more efficient models, resulting in increased energy expenses and a larger carbon footprint.
Safety risks are heightened with inadequately maintained conveyors. Hazards to workers may include entrapment, entanglement, and noise-induced hearing loss. Furthermore, outdated conveyors can waste resources such as labor, materials, and equipment due to inefficient material flow and handling. They may also lack compatibility with new equipment or technologies, limiting the ability to integrate modern systems and processes effectively.
DC vs AC – CBA
Considering the advantages and disadvantages of DC and AC motors for your application will help you make an informed choice before you explore your needs further.
DC Motors offer :
- Precise speed control and zero-speed torque
- Suitable for applications with frequent starts and stops
- Can operate in reverse
- Less maintenance is required due to the lack of brushes
Disadvantages:
- Higher cost compared to AC motors and have a limited power range (typically up to 10 HP)May require additional components (e.g., controllers, sensors)
AC Motors offer:
- Lower cost compared to DC motors
- Higher power range (up to 100 HP or more)
- Simple and robust design
- Can operate with a wide range of voltages and frequencies
Disadvantages:
- Coarser speed control and reduced zero-speed torque. It may require additional components (e.g., VFDs, soft starters) for speed control and protection. It can also generate harmonics and electromagnetic interference (EMI)
When retrofitting a conveyor system, choosing between DC and AC motors depends on the specific requirements of your application, such as load characteristics, speed control needs, and the existing infrastructure.
- If the current conveyor system is designed for AC power, upgrading to a new AC motor may be more cost-effective and straightforward. On the other hand, if the system is designed for DC power, retrofitting with a DC motor may be more appropriate.
- For conveyor systems with high inertia loads or those that require precise speed control, a DC motor may be a better option. In contrast, an AC motor would be sufficient for lighter loads or applications with less strict speed control needs.
- If the retrofit demands minimal changes to the existing layout or requires easy access for maintenance, a DC motor might be preferred. AC motors, however, may need more space and modifications to accommodate variable frequency drives (VFDs) or other control equipment.
- Modern AC motors equipped with VFDs can provide greater energy efficiency than DC motors. The overall energy savings will depend on the specific application and load conditions.
Analyzing these factors will help you identify the most suitable motor type for your project. If your business requires a unique conveyor system, consider collaborating with a motor expert, manufacturer, or integrator to create a custom solution that meets your specific needs. Retrofitting your existing MDR conveyor with new components or technologies can help minimize downtime and reduce costs.
Motor-Driven Rollers
(MDR) conveyors are popular in many industries due to their energy efficiency, low maintenance requirements, and flexibility. However, there are circumstances where replacing an MDR conveyor may be necessary.
MDR conveyors have evolved and newer models have enhanced performance or efficiency features. Like any mechanical system, MDR conveyors can wear out over time. Replacing worn-out components or the entire conveyor may be essential to maintain productivity and product quality. Additionally, changes in production volumes, product sizes, or packaging requirements might require an upgrade or replacement of the conveyor system. If your facility undergoes renovations or expansions, you may need to replace an MDR conveyor to accommodate new equipment or layouts.
Options for Replacing an MDR Conveyor:
If your current MDR conveyor is still functional but outdated, consider upgrading to a newer model with improved features and performance. Depending on your specific needs, you might consider replacing an MDR conveyor with a different type, such as:
- Belt conveyor
- Chain conveyor
- Roller conveyor (non-motorized)
- Pallet conveyor
- Accumulation conveyor
Interoll conveyor
The Interroll MDR conveyor is a versatile and efficient powered roller conveyor system offering numerous advantages. Its adaptability for various applications and customizable options make it an ideal solution for many industries. The MDR conveyor features motorized rollers, which eliminates the need for traditional power transmission components, resulting in a compact and efficient design. One of the standout features of the Interroll conveyor is its ability to allow independent control of each zone, enabling true zero-pressure accumulation. This design minimizes energy waste and reduces the risk of product damage or congestion. Notably, the rollers stop turning when no product is detected, which saves energy and decreases noise output by 50-75% compared to conventional belt conveyor systems.
The Interroll conveyor can also be tiered to save vertical space, making it suitable for applications with limited floor area. The system operates more quietly than traditional conveyors due to smaller motors and the absence of chains and sprockets, creating a more comfortable work environment. MDR conveyors utilize 24VDC motors, which require significantly less power than traditional 480VAC systems. For instance, a conventional 480VAC belt conveyor system with 18 drives and 14 power supplies would consume approximately 223,816 kWh per year, leading to annual energy costs of $17,905. In contrast, an Interroll MDR conveyor system with 360 zones and 14 power supplies would consume around 87,010 kWh annually, resulting in yearly energy costs of $6,960. This represents annual savings of $10,945, reflecting a 50% reduction in energy consumption.
AI project management
Atlantic Installation has over 35 years of experience in managing large-scale projects. As a partner of Rolling on Interroll, we gain unique insights and advantages in designing, retrofitting, and installing conveyor systems for your facility. Our process begins with a thorough inspection of your facility and equipment. We collaborate closely with you to understand your goals and conceptualize the best solutions. After this assessment, we design and implement updated technology into your system by working within your timeline to ensure your equipment is functional and operational when you need it.
When you choose to retrofit your current conveyor, we ensure that you receive the latest and most advanced equipment to promote streamlined and efficient workflows with minimal downtime for your operations. We adhere to compliance protocols and industry standards throughout the process. Contact us to get started on upgrading your conveyor systems.Â