The highest compliment a gearbox can earn

“Put a STOBER on it and forget it.”

That’s how a maintenance planner at a major poultry processing facility describes the company’s experience with STOBER equipment.

It’s a simple statement, but in a food processing operation where failed motors and gearboxes can mean costly downtime, it’s also a powerful compliment.

Just a few years earlier, the facility was dealing with recurring gearbox and motor failures on several conveyor applications. Some systems required two to three replacement units each year, creating excessive downtime, rising replacement costs and ongoing maintenance challenges. As reliability issues continued to impact production, the facility began searching for a long-term solution.

Reliability challenges drive the search for a better solution

Like many food processing facilities, the plant operates in a demanding environment where equipment is expected to perform under continuous use and frequent washdowns. According to the project team, many of the existing motors and gearboxes had originally been sized without adequate service factors for the application, resulting in premature failures and increased maintenance requirements.

As downtime and replacement costs mounted, the facility launched a cost-savings initiative aimed at improving reliability and reducing long-term operating expenses. That search ultimately led the team to STOBER.

Building a solution around the application

STOBER worked closely with the customer’s maintenance team to evaluate the affected applications and determine the best path forward. The final solution included multiple KSS2 and KSS4 units equipped with the complete cLEAN System on several high-demand material handling and conveyor applications throughout the facility.

The project represented more than a product replacement. STOBER personnel conducted plant visits, tested operating conditions and reviewed application data with the maintenance team. During testing on the material handling conveyors, STOBER identified torque surges occurring several times each hour and collaborated with plant personnel to develop a solution that could withstand those demands.

The cLEAN System was designed specifically for food and beverage washdown environments. The system combines a stainless steel KSS gearbox, permanent magnet motor, drive and cable package engineered to resist water ingress, corrosion and contamination while improving energy efficiency and reducing maintenance requirements. The system also carries a three-year warranty covering the gearbox, motor, drive and cable.

Proven performance builds confidence

One factor played a significant role in the customer’s decision: previous experience.

Before the larger cLEAN System installation, STOBER equipment was already operating on another critical conveyor application within the facility. According to the project team, those gearboxes had been in service for six years without a breakdown. That proven performance gave the maintenance team confidence that STOBER could help solve reliability issues in other areas of the plant.

Fast installation backed by engineering support

Once the customer selected the cLEAN System for the critical conveyor applications applications, implementation moved quickly.

Working alongside the plant maintenance team and with support from STOBER engineering staff, four units were installed and commissioned in approximately nine hours with no reported issues. Prior to installation, STOBER held a pre-installation meeting with the maintenance team to review the process and ensure everyone was aligned. Throughout the installation, engineering support remained readily available.

The maintenance team had initially expressed concerns about programming and integrating the variable frequency drive. According to the project team, those concerns were quickly eliminated once commissioning began, and the team found the drive easy to configure and integrate with existing systems.

Measurable results

The reliability improvements were immediate and measurable.

According to the project team, the conveyor application has operated for three years without a breakdown. The critical conveyor application installations have also operated without failures since installation.

The operational improvements translated directly into cost savings.

A documented cost-savings report for the facility showed:

• $140,068.81 in realized reliability savings
• $16,869.80 in realized energy savings
• $24,735.15 in realized oil savings
• $157,579.38 in realized gearbox savings
• $158,920.71 in total documented savings

For a facility that originally began its search as a cost-reduction initiative, the project delivered measurable financial returns while improving day-to-day operational reliability.

Looking ahead

The results have encouraged the customer to continue evaluating additional applications for STOBER products. The facility is already planning another conveyor project utilizing the cLEAN System.

For the maintenance team, however, the project’s success may be best summarized by a single quote:

“Put a STOBER on it and forget it.”

In an industry where maintenance teams spend their days responding to equipment problems, there may be no higher compliment.

From improved reliability to documented cost savings, manufacturers are turning to STOBER to solve some of their toughest operational challenges. Discover how other companies are achieving measurable results with STOBER power transmission solutions.