Download Soda Manufacturer Drinks in Savings of $73K with RUS

Rexnord Total Cost of Ownership
Customer
Soft drink manufacturer
Industry
Food & Beverage
Application
Bottle conveyor to palletizer
Rexnord Solution:
Roller Upgrade System (RUS)
with High-Performance, Low
Backline Pressure Rollers
Total Annual Savings
$73,592
Soda manufacturer drinks in savings
of $73K with Roller Upgrade System.
Challenge
A global leader in the beverage industry was
conveying containers of cans and two-liter bottles
of soda over four powered roller conveyors. The
lines were mostly suspended overhead, and
conveyed soda cases up an incline to palletizers.
The two lines transporting cases of PET bottles
were old, with many of the rollers no longer turning.
As a result, containers were stranded weekly and
required the use of a manlift to reach and dislodge
them. In addition to lost production, jam ups from
the stranded containers caused excessive wear on
the incline conveyors and necessitated frequent
replacement of the rollers and roller drive O-rings.
Soda cases got stranded on the powered
roller conveyor, causing downtime to
retrieve product from the suspended line.
Rexnord Solution
Rexnord proposed upgrading two of the existing
roller conveyors to a trouble-free modular chain
using the Rexnord Roller Upgrade System. The
easy-to-install system includes a chain, support
brackets, wear strips and Rexnord’s unique drive
shaft support module. Adaptable to many common Rexnord’s Roller Upgrade System
resulted in 90% annual savings.
roller or belt conveyor installations, the Roller
Upgrade System would provide smooth, high-speed
case conveying, while eliminating lost production and
maintenance costs.
Rexnord Solutions and Savings in Action
By installing the Roller Upgrade System, the soft drink manufacturer was able to
save $18,800 in maintenance costs because they no longer needed to replace
the conveyor rollers and broken O-rings or deal with the product jam ups. More
importantly, the customer eliminated the weekly lost production costs associated
with retrieving stranded product, thus saving $62,400 annually. Based on the
successful performance of the Roller Upgrade System, the customer plans to install
the same system at another plant.
For a detailed cost analysis for
your application, contact your
local Rexnord Representative.
TCO4-012
Rexnord Total Cost of Ownership
Calculating the Annual Total Cost of Ownership (TCO)
Rexnord worked with the customer to determine their current cost of ownership and compared that
to the cost of the Rexnord solution. Factors considered were:
• Acquisition costs of the Roller Upgrade System
• Installation costs
• Reduced maintenance events
• Lost production due to downtime
Annual Cost Analysis Breakdown
Replace Rollers
Events/Year
Labor Cost/Event
Material
Cost/Event
Total
36
$200
$200
$14,400
Events/Year
Labor Cost/Event
Material
Cost/Event
Total
2
$1,200
$1,000
$4,400
Current product
Roller Upgrade System would eliminate this cost.
Replace Live Roller Rubber Belts
Current Product
Roller Upgrade System would eliminate this cost.
Lost Production
Repair conveyors and remove stranded product
Events/Year
Downtime
Cost/Hour
Total
52
$1,200
$62,400
Current Product
Roller Upgrade System would eliminate this cost.
Total Current Annual TCO $81,200
RUS Acquisition & Conversion Costs
Annualized based on 7 years life
Cost
Expected Life
(Years)
Annual Cost
Installation labor
$19,999
7
$2,857
Materials
$33,257
7
$4,751
Total Annual RUS Cost $53,256
$7,608
Rexnord Solution Annual Savings Summary
Total current cost
$81,200
Total proposed cost
Total savings per year
TCO reduction percent
$7,608
$73,592
90.6%
Total Cost of Ownership Annual Savings: $73,592
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©2012 Rexnord Corporation
• www.rexnord.com
TCO4-012 Printed in USA 3/12