Product Development

The MultiDrive: A safeguard against total failure

Published

8 years ago

October 31, 2017

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Thanks to the electrical and mechanical redundancy, the mill can continue to run even in the unlikely event of the failure of a drive unit with the MultiDrive drive system.

The MultiDrive drive system that has proved successful in practice since 2009 was developed by Gebr. Pfeiffer in conjunction with Siemens/Flender specifically for driving the MVR vertical roller mill (Fig 1). Unlike virtually any other mill drive system the MultiDrive offers maximum availability and therefore provides the greatest possible security against possible total failure (Fig 2). The mill is driven through a girth gear flanged to the grinding bowl by up to six actively redundant drive units with a total output of up to 18,000 kW (Fig 3), each consisting of an electric motor, coupling and gear unit. The use of this drive system means that the gear units are not exposed to the grinding forces (Fig 4). Thanks to the electrical and mechanical redundancy the mill can continue to run even in the unlikely event of the failure of a drive unit. Driving the MVR vertical roller mill with a MultiDrive represents a crucial step forward not just because of the opportunity for transmitting high drive ratings. The MVR vertical roller mill equipped with the MultiDrive drive system is still available for operation even if a roller has to be taken out of the grinding process. The advantages are no unplanned stoppages and a very high production capacity at all times. The installation of just one mill achieves availabilities and outputs that would otherwise require two vertical roller mills set up in parallel.

Completed plants, tests and operating results
Since their introduction in 2009 [1] the MVR mills equipped with the MultiDrive drive system have been submitted to tests and extensive operating experience has been gathered.

A pilot plant equipped with a MultiDrive with three drive units in an MPS 4750 BC vertical roller mill was commissioned in 2009 in a cement plant belonging to HolcimLafarge in France.
This pilot plant and the subsequent operational plants (Table 1) were submitted to intensive testing.
The tests and analyses led to ongoing improvements to the MultiDrive drive system.
At the same time a modular MultiDrive construction system was developed with different sizes of grinding bowl support systems.
There are now five MultiDrive drives in operation with variable speed adjustment and one MultiDrive drive with fixed speed is being delivered. So far 31 KMRS 220 gear units were built.

The MultiDrive drive system is an alternative drive system for vertical roller mills that now combines long-term operating experience with great operating results. The drive system was systematically improved against the background of the experience that had been obtained. The operating experience and test results are described using three examples of different mill sizes.

MPS 4750 BC vertical roller mill at Val de Seine, France
The mill is driven through a MultiDrive drive system equipped with three drives with a total installed rating of 4 350 kW.

Investigation: The mill was operated for several days with (n-1) drives during which the displacement of the drive flange was measured.

Results

The direction of displacement was established as assumed and a smaller displacement than expected was measured (Fig. 5).
There were no problems with continuous operation in this operating state.
From stopping the mill to re-starting it the time taken for disengaging a drive was 8 h.

MVR 5600 C-4 vertical roller mill in Balaji, India
The mill is driven through a MultiDrive drive system consisting of four drives with a total installed rating of 6 600 kW.
Investigation: The mill was operated with (n-1) rollers. The roller was raised and secured. Various measurements were carried out during the operation with (n-1) rollers.

Results

Operation with (n-1) rollers was, as expected, possible.
Apart from the output the process engineering parameters were unchanged. The output achieved was 85 per cent.
The fluctuations in power consumption, rotational speed, current input and measured torque were higher than during the operation with all rollers. The torque fluctuations, for example, rose from ? 10 to ? 20 per cent.
The smoothness of running proved to be practically unchanged.
The displacement of the drive flange of the grinding bowl support system was as expected (Fig. 6).
No abnormalities were detected in the pad bearing pressures, e.g. pressure irregularities due to bearing displacement.
There were no problems with continuous operation in this operating state.

MVR 6700 C-6 vertical roller mill at Barroso, Brazil
The Barroso MVR 6700 C-6 vertical roller mill in Brazil is the most powerful vertical roller mill in operation that is used for grinding cement. The mill is driven by a MultiDrive drive system with six drives with a total installed rating of 11,500 kW. The MultiDrive is equipped with frequency converters that allow the grinding bowl speed to be adjusted to suit the different product grades.

Since April 2016 the mill has been in operation to the complete satisfaction of the operator, who reported in a lecture in December 2016 in Fort Lauderdale on the remarkable quietness of running of the MVR mill [2] and emphasized the flexibility of the plant that makes it possible to product a wide variety of types of cement. The progress of the commissioning of the grinding plant was also described as very satisfactory so that after only 79 operating hours the mill could be operated without the presence of a GP supervisor.

The capital investments costs (CAPEX) for the new cement production line in the cement plant belonging to the HolcimLafarge Group were reduced by about 25 per cent through the use of the MVR mill with MultiDrive.

The MultiDrive? against the background of specific customer demands

Demands based on the example of large cement mills (> 9 000 kW): According to Harder [3], vertical roller mills with installed drive ratings of up to 5 000 kW lie in the small to medium power range, mills with drive ratings of 5,000 to 9,000 kW are classified as large mills and above this are very large mills.

In projects where the mills have drive ratings > 9,000 kW the standard for mill suppliers has been set very high: high outputs with reduced production costs and increased efficiency with the ability to produce different blended cements under conditions of comparatively low total investment. In addition to this it is necessary to fulfill the demands for very high plant availability and sophisticated maintenance schemes so that the cost per tonne of cement produced can be kept permanently at a fairly low level. Today’s customers favour the one-line principle to fulfil the requirement for low total investment, but only on the condition that total failure of cement production can be ruled out by guaranteeing excellent availability of the grinding system.

The total drive power of 11,500 kW needed to obtain an output of 450 t/h in the example of the "Barroso" mill cannot be achieved with conventional drive systems. Gebr. Pfeiffer is now in the position to offer the most suitable drive solution for this and comparable requirements at the lowest possible CAPEX costs.

Advantages of the MultiDrive multiple drive system
The customers’ demands can be met individually through carefully developed and well engineered strategies so that the MultiDrive drive system combines the advantages:

Modularity

2, 3, 4, 5 or 6 identical drive units, each consisting of motor, coupling and gear unit, drive the girth gear of the grinding bowl support system with a total installed rating of up to 18 000 kW.
KMRS 2200 and KMRS 2540 gear units are used in the drive units. Engineering
Patented innovative solutions.
Drive of the grinding bowl with variable or constant rotational speed.
The MultiDrive? drive system represents a successful solution for driving the MVR vertical roller mill and the use of space-saving twin supports means that there are also appropriate lanes for removing the grinding bowl support system.
The radial bearing using pivoted shoe technology is dimensioned to take dynamic radial forces from the grinding operation as well as static radial forces from operation with (n-1) rollers and (n-1) drives.

Active redundancy: The MultiDrive? drive system increases the MVR vertical roller mill’s great potential. Operation of the mill with (n-1) rollers and (n-1) drives was verified successfully during the test operation. The MVR vertical roller mill has a high degree of mechanical and electrical redundancy and, in contrast to mills and drive systems in which the failure of a single component leads to a production stoppage, can maintain production operation.

Space- and cost-saving design: The use of the MultiDrive drive system facilitates the lowest overall height of all the mill drive systems on the market and means that the MVR grinding plants can be built very compactly and economically.

The grinding forces act on the base with a small lever arm and are directed conveniently into the foundation.

Flexible through variable grinding speed: The MultiDrive drive system can, if required, be operated at varying speeds using frequency converters. In many cases it is possible to dispense with the speed control but a frequency converter can be retrofitted at any time if the requirements change.

Simple maintenance: The drive units are positioned radially on mounts so they are easy to pull out from under the mill and can then be picked up with a crane. With a maximum weight of 25 t per KMRS- 2200 drive unit this ensures comparatively greater ease of maintenance.

Efficient stock-holding: The stock-holding is simpler and more economical due to the simple modular design based entirely on standard components. A drive unit can also be used in other mills that are driven by a MultiDrive drive system.

Optimum plant profitability (ROI, TCO): Unlike any other mill drive system, unplanned stoppage times are reduced to a minimum. Even with unplanned stops the one-mill solution using an MVR vertical roller mill, when compared with a two-mill solution, gives a better rate of return in the long term thanks to its high level of availability.

Costs/ROI: An examination of costs shows that the use of the MVR vertical roller mill equipped with the MultiDrive drive system is also characterized by a favourable cost/benefit ratio. This is shown in ?Table 2 and ?Fig 7 based on the example of an MVR cement mill with six rollers and an output of 270 t/h when compared with a mill of the same capacity with three grinding rollers. If one of the six rollers in the MVR mill has to be taken out of operation for maintenance reasons the output falls to 84 (?Fig. 8). If, with the other mill with three rollers, one roller is taken out of operation then the mill can no longer be operated – the output drops to zero. With a basic cement price of $60/t and an assumed outage time of five days there is a loss of sales revenue with the MVR mill equipped with the MultiDrive drive system of about $3,00,000. For the competitor mill it is almost $20,00,000.

Differentiation from other drive systems
In conventional mill drives the gear unit not only transmits the power from the motor to the grinding bowl but also carries the grinding forces down into the foundation. The MultiDrive drive system is currently the only drive solution on the market that separates these two processes. The advantage is that there is no additional loading by axial and radial grinding forces.

Harder [3] also counts the COPE drive from Renk [4] among the multiple drives. The COPE-Drive builds up high and slim, so that it can pass through the narrow gap between the single support (?Fig.8) With the comparatively clean MultiDrive-concept, there are not many single components under the mill where the access is very difficult, so that with the MultiDrive it is, for example, simpler to remove a motor (Fig 9 & 10).

A robust and flat grinding bowl support system is used for the MVR grinding bowl through the use of space-saving twin supports as there is sufficient space for its installation and removal. This grinding bowl support system is capable of taking static radial forces from the operation of the mill with (n-1) rollers and (n-1) drives (see Fig. 4). Dynamic radial forces amounting to 30 per cent of the axial force are also taken in accordance with the customer’s design criteria.

The advantages of driving the MVR vertical roller mill with a MultiDrive were verified in tests on operating plants. Even with very large production units a level of availability never previously obtained is achieved through the active redundancy of the mill and MultiDrive. Apart from the comparatively favourable total investment cost the implementation of the one-mill technology is therefore very important for the grinding plants in both the raw meal and cement departments. Figs. 11 and 12 show the MultiDrive drive system in the cement mills at HolcimLafarge’s Biskra and Barroso cement plants..

Outlook
An MVR vertical roller mill, driven by a MultiDrive with four drives, is currently being delivered to a cement plant in Cambodia and a mill driven by a MultiDrive with four variable-speed drives is being processed for a customer in Pakistan. Not only the advantages with the OPEX costs but also optimized CAPEX costs have become apparent now that the MultiDrive drive system has been examined from the value analysis point of view.

References
[1]Hoffmann, D.; Reichardt, Y.; Sch?tte, K.-H.: The MVR vertical roller mill plus MultiDrive? a successful combination. CEMENT INTERNATIONAL 9 (2011) No. 2, pp. 44-19.
[2]HolcimLafarge-Vortrag auf dem "Gebr. Pfeiffer ready- 2grind Technical Panel", Fort Lauderdale, Dec 2016.
[3]Harder, J.: Drives for large vertical roller mills. ZKG International (2017) No. 1/2, pp. 32-39.
[4]Broschure of Renk about the COPE-Drive, edition 02.2015.
[5]XXXI Congresso Tecnico FICEM. Federacion Interamericana del Cemento, Santo Domingo, Republica Dominicana, 2014.
[6]19th Arab International Cement Conferenz and Exhibition, November 2014.

– The article is authored by D. Hoffmann, L. Schmitt, Gebr. Pfeiffer SE, Kaiserslautern, Germany

Economy & Market

Power Build’s Core Gear Series

Published

3 weeks ago

February 19, 2026

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A deep dive into Core Gear Series of products M, C, F and K, by Power Build, and how they represent precision in motion.

At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. Power Build answers this need with its flagship geared motor series: M, C, F and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.

Series M – Helical Inline Geared Motors
Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.

Series C – Right Angled Heli-Worm Geared Motors
Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.

Series F – Parallel Shaft Mounted Geared Motors
Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.

Series K – Right Angle Helical Bevel Geared Motors
For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining and material handling. Its flexibility in mounting and broad motor options offer engineers the freedom in design and reliability in execution.
Together, these four series reflect Power Build’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design and field-tested reliability. Whether the requirement is speed control, torque multiplication or space efficiency, Radicon’s Series M, C, F and K stand as trusted powerhouses for global industries.

http://www.powerbuild.in
Call: +919727719344

Economy & Market

Conveyor belts are a vital link in the supply chain

Published

9 months ago

June 16, 2025

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Kamlesh Jain, Managing Director, Elastocon, discusses how the brand delivers high-performance, customised conveyor belt solutions for demanding industries like cement, mining, and logistics, while embracing innovation, automation, and sustainability.

In today’s rapidly evolving industrial landscape, efficient material handling isn’t just a necessity—it’s a competitive advantage. As industries such as mining, cement, steel and logistics push for higher productivity, automation, and sustainability, the humble conveyor belt has taken on a mission-critical role. In this exclusive interview, Kamlesh Jain, Managing Director, Elastocon, discusses how the company is innovating for tougher terrains, smarter systems and a greener tomorrow.

Brief us about your company – in terms of its offerings, manufacturing facilities, and the key end-user industries it serves.
Elastocon, a flagship brand of the Royal Group, is a trusted name in the conveyor belt manufacturing industry. Under the brand name ELASTOCON, the company produces both open-end and endless belts, offering tailor-made solutions to some of the most demanding sectors such as cement, steel, power, mining, fertiliser, and logistics. Every belt is meticulously engineered—from fabric selection to material composition—to ensure optimal performance in tough working conditions. With advanced manufacturing facilities and strict quality protocols, Elastocon continues to deliver high-performance conveyor solutions designed for durability, safety, and efficiency.

How is the group addressing the needs for efficient material handling?
Efficient material handling is the backbone of any industrial operation. At Elastocon, our engineering philosophy revolves around creating belts that deliver consistent performance, long operational life, and minimal maintenance. We focus on key performance parameters such as tensile strength, abrasion resistance, tear strength, and low elongation at working tension. Our belts are designed to offer superior bonding between plies and covers, which directly impacts their life and reliability. We also support clients
with maintenance manuals and technical advice, helping them improve their system’s productivity and reduce downtime.

How critical are conveyor belts in ensuring seamless material handling?
Conveyor belts are a vital link in the supply chain across industries. In sectors like mining, cement, steel, and logistics, they facilitate the efficient movement of materials and help maintain uninterrupted production flows. At Elastocon, we recognise the crucial role of belts in minimising breakdowns and increasing plant uptime. Our belts are built to endure abrasive, high-temperature, or high-load environments. We also advocate proper system maintenance, including correct belt storage, jointing, roller alignment, and idler checks, to ensure smooth and centered belt movement, reducing operational interruptions.

What are the key market and demand drivers for the conveyor belt industry?
The growth of the conveyor belt industry is closely tied to infrastructure development, increased automation, and the push for higher operational efficiency. As industries strive to reduce labor dependency and improve productivity, there is a growing demand for advanced material handling systems. Customers today seek not just reliability, but also cost-effectiveness and technical superiority in the belts they choose. Enhanced product aesthetics and innovation in design are also becoming significant differentiators. These trends are pushing manufacturers to evolve continuously, and Elastocon is leading the way with customer-centric product development.

How does Elastocon address the diverse and evolving requirements of these sectors?
Our strength lies in offering a broad and technically advanced product portfolio that serves various industries. For general-purpose applications, our M24 and DINX/W grade belts offer excellent abrasion resistance, especially for RMHS and cement plants. For high-temperature operations, we provide HR and SHR T2 grade belts, as well as our flagship PYROCON and PYROKING belts, which can withstand extreme heat—up to 250°C continuous and even 400°C peak—thanks to advanced EPM polymers.
We also cater to sectors with specialised needs. For fire-prone environments like underground mining, we offer fire-resistant belts certified to IS 1891 Part V, ISO 340, and MSHA standards. Our OR-grade belts are designed for oil and chemical resistance, making them ideal for fertiliser and chemical industries. In high-moisture applications like food and agriculture, our MR-grade belts ensure optimal performance. This diverse range enables us to meet customer-specific challenges with precision and efficiency.

What core advantages does Elastocon offer that differentiate it from competitors?
Elastocon stands out due to its deep commitment to quality, innovation, and customer satisfaction. Every belt is customised to the client’s requirements, supported by a strong R&D foundation that keeps us aligned with global standards and trends. Our customer support doesn’t end at product delivery—we provide ongoing technical assistance and after-sales service that help clients maximise the value of their investments. Moreover, our focus on compliance and certifications ensures our belts meet stringent national and international safety and performance standards, giving customers added confidence.

How is Elastocon gearing up to meet its customers’ evolving needs?
We are conscious of the shift towards greener and smarter manufacturing practices. Elastocon is embracing sustainability by incorporating eco-friendly materials and energy-efficient manufacturing techniques. In parallel, we are developing belts that seamlessly integrate with automated systems and smart industrial platforms. Our vision is to make our products not just high-performing but also future-ready—aligned with global sustainability goals and compatible with emerging technologies in industrial automation and predictive maintenance.

What trends do you foresee shaping the future of the conveyor belt industry?
The conveyor belt industry is undergoing a significant transformation. As Industry 4.0 principles gain traction, we expect to see widespread adoption of smart belts equipped with sensors for real-time monitoring, diagnostics, and predictive maintenance. The demand for recyclable materials and sustainable designs will continue to grow. Furthermore, industry-specific customisation will increasingly replace standardisation, and belts will be expected to do more than just transport material—they will be integrated into intelligent production systems. Elastocon is already investing in these future-focused areas to stay ahead of the curve.

Economy & Market

Impactful Branding

Published

3 years ago

July 17, 2023

admin

Advertising or branding is never about driving sales. It’s about creating brand awareness and recall. It’s about conveying the core values of your brand to your consumers. In this context, why is branding important for cement companies? As far as the customers are concerned cement is simply cement. It is precisely for this reason that branding, marketing and advertising of cement becomes crucial. Since the customer is unable to differentiate between the shades of grey, the onus of creating this awareness is carried by the brands. That explains the heavy marketing budgets, celebrity-centric commercials, emotion-invoking taglines and campaigns enunciating the many benefits of their offerings.
Marketing strategies of cement companies have undergone gradual transformation owing to the change in consumer behaviour. While TV commercials are high on humour and emotions to establish a fast connect with the customer, social media campaigns are focussed more on capturing the consumer’s attention in an over-crowded virtual world. Branding for cement companies has become a holistic growth strategy with quantifiable results. This has made brands opt for a mix package of traditional and new-age tools, such as social media. However, the hero of every marketing communication is the message, which encapsulates the unique selling points of the product. That after all is crux of the matter here.
While cement companies are effectively using marketing tools to reach out to the consumers, they need to strengthen the four Cs of the branding process – Consumer, Cost, Communication and Convenience. Putting up the right message, at the right time and at the right place for the right kind of customer demographic is of utmost importance in the long run. It is precisely for this reason that regional players are likely to have an upper hand as they rely on local language and cultural references to drive home the point. But modern marketing and branding domain is exponentially growing and it would be an interesting exercise to tabulate and analyse its impact on branding for cement.