Vanmark UPTIME™ May, 2004
Conversion from Hydraulics (continued) ...
Simply put, hydraulic units cost more to operate, primarily because a high percentage of the energy put in is lost in the form of heat. To compensate, a much larger motor is needed to power a hydraulic unit than for a similarly sized electro-mechanical unit. To avoid overheating, the waste heat generated has to be constantly dissipated by a heat exchanger.
Unfortunately, the heat exchangers required take even more energy to run and often the waste heat is simply exhausted into the building. Most exchangers also use water as the cooling medium which is passed through and then disposed, which adds even more to the overall cost of operation.
Hydraulic drives are also typically not as clean as their electric counterparts due to inevitable oil leaks, failed hoses, or broken pipes, which leads to further inefficiency. Plus there is the obvious potential of product contamination as well.
An often overlooked disadvantage of hydraulic drives is the difficulty in troubleshooting when something goes wrong. While a relatively inexperienced maintenance person can easily spot a broken belt or pulley in an electro-mechanical system, it is much more difficult to analyze a failing valve, why one roll isn’t turning as fast as it should be, or the cause of an overheating problem. The additional downtime for diagnosing and fixing the problem can be a significant hidden extra cost of operation.
Although it might be nice to have the budget to buy replacement equipment, for most plant operators, this just isn’t reality any time soon. So, short of replacement, what are the options? Over the past several years, Vanmark has helped a number of customers convert their Vanmark peelers and scrubber/washers from hydraulic to electro-mechanical drive systems. We have developed kits which contain the components necessary to make the conversion. The cost and complexity of conversion depends on your machine model and installed options.
One of the required components is an inverter. This allows the single speed drive motor to become a variable speed motor. While Vanmark can and supply the inverter, many customers prefer to purchase this component separately. This is due the fact that many customers have standardized on a preferred brand chosen from large number of brands available on the market. Just as it is difficult for our customers to maintain relationships with a large number of vendors for the same type of item, it is also difficult for us. We will be happy to discuss this and other aspects of the conversion process with you at the time of your inquiry.
The benefits of conversion are many but, as with any investment, one has to look not only at the expected short term ROI, but at the bigger picture involving long term goals and strategies for success. There are often outside influences beyond our control. For example, the choice is often influenced heavily by budgetary policy alone, i.e. funding may be available for maintenance and improvements, but not for capital purchases.
For some, conversion may be the obvious answer to reducing operating costs and improving overall plant efficiency. For others, the decision may seem less clear or definitely not the right way to go. Each situation is different and must be evaluated on its own merits.
If you would like to discuss possible conversion of your hydraulic units, we would be pleased to help. Call or email your Vanmark representative or contact
one of our application specialists directly at
800-523-6261 or
sales@vanmarkequipment.com.