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How planetary gear system can help you save you power as compared to the traditional worm and open gear system
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Energy conservation
using Planetary
crystallizersTraditional technology compared with the latest
technology!
© Kavitsu Group
Energy conservation:
Electrical energy is one of the most essential part of
our daily lives.
The resources are fast depleting, the requirement is
increasing exponentially.
To overcome this issue, the government has made it
mandatory to the sugar mills to have co-generation
plants in the premises.
But there are other ways to save the power!!
© Kavitsu Group
The traditional drive system:
The conventional systems in olden days used a
combination of electric motor belt pulley, coupled
with worm and worm wheel gear set in open
condition.
It was less efficient and incurred higher maintenance
costs.
The new technology, Planetary gear, is much more
efficient.
© Kavitsu Group
Planetary gear Vs Worm gear
Worm gear system Planetary gear system
Power
consumption
High power ~ 30 HP Low power Max. 7.5 HP
Efficiency Very poor, upto 30% due to heavy
mechanical losses
Highly efficient, 90% due to compact
and sealed design
Handling Difficult due to heavy design Very easy since it is lightweight and
compact
Hand operation
during power
failure
Difficult due to higher volume and
greater inertia
A single person can easily rotate due to
its lower inertia and proper lubrication
Installation Alignments have to be done with
extreme caution. Phosphorus bronze
bearings have to be used which have
very short life span. They tend to
damage other components as they
generate micro particles which in turn
increase wear and tear
It is directly mounted on crystallizer
shaft. No wear and tear to other parts
as it is completely sealed
Maintenance Costlier, due to wear and tear as the
gearing system is open
Only maintenance is the oil change at
certain intervals
Cleanliness Since the components are in open
condition, foreign particles gather in the
gears and they can damage other
components. Also, oil spillage is
maximum, which adds to the damaged
environment and higher maintenance
costs
The housing is completely sealed and
no foreign particle can enter the
system. This ensures clean surroundings
and less maintenance costs.
Advantages:
Easy to handle due to compact form factor and it
being light weight
Fits directly on the crystallizer shaft and thus eliminates
the alignment issues.
Long life due to hardened gears and properly
lubricated assembly
Low overhead costs due to less power consumption
Can be used for all types of crystallizers: water cooled,
air cooled, vacuum; horizontal and vertical.
© Kavitsu Group
Energy savings:Size of sugar plant 5000 TCD
Number of crystallizers used 15
Power using conventional system 10 HP
Total power consumed 150 HP
Planetary drive power consumed ( Kavitsu planetary drives)
3 HP
Total power consumed using Kavitsu drives 45 HP
Total power saved 105 HP
Considering 150 days season total economical benefits
INR 1.15million
© Kavitsu Group
Kavitsu Planetary Crystallizer drives
© Kavitsu Group
Kavitsu Planetary Crystallizer drives
Supplying high quality gearboxes and sugar crystallizer
drives to sugar industry since 1998
Compact form factor and reliable
Less maintenance required
Easy to install
Range starts from 20 MT to 1000 MT
Available in both horizontal ( 20 MT to 110 MT) and
Vertical ( 120 Mt to 1000 MT) mountings
© Kavitsu Group
© Kavitsu Group
Case studies: Someshwar sahakari sakhar karkhana, Baramati
© Kavitsu Group
Crystallizer Capacity
/type
Previously
installed HP
Power with
Kavitsu gear
box
Current rating
previously
Current rating
at present
Quantity
1,2,3 65 / A 15 5 7.3A 2.91A 03 NOS
4,5 50 / A 10 3 4.6A 2.15A 02 NOS
6 - 15 40 / B 7.5 2 34A 2.08A 10 NOS
Total savings = OLD HP – NEW HP
= 140 HP – 41 HP
= 99 HP ( 64.48% power saved!)
Malegaon sahakari sakhar karkhana ltd, baramati (pune)
CRY NO.CAPACITY
TONNE/ TYPE
PREVIOUSLY
INSTALLETED
HOURSE
POWER
POWER WITH
KAVITSU GEAR
BOXES
RATES
CURRENT OF
MOTOR
CURRENT
READINGSQTY IN NOS.
1 110 / A 25 5 7.3 A 3.50 A 1
2, 3 65 / A 25 3 4.6 A 2.21 A 2
4, 5, 6 40 / A 7.5 2 3.4 A 2.28 A 3
7 TO 10 40 / B 10 2 3.4 A 1.68 A 4
11, 12, 13 40 / C 15 2 3.4 A 2.60 A 3
14 35 / SEED B 10 2 3.4 A 2.50 A 1
15 30 / SEED B 5 1.5 2.6 A 1.74 A 1
16 25 SEED DRY 5 1.5 2.6 A 1.40 A 1
17 300 VERT / B 25 5 7.3 A 5.60 A 1
18 450 VERT / B 75 20 34 A 29 A 1
© Kavitsu Group
TOTAL SAVINGS = OLD INSTALLED HP - NEW INSTALLED HP
= 302.5 HP - 60 HP
= 242.5 HP (80.16% Savings)
Our location:
HQ : W -85, ADDITIONAL MIDC, SATARA 415 004, MAHARASHTRA,
(INDIA)
Works: J -12, ADDITIONAL MIDC, SATARA 415 004, MAHARASHTRA,
(INDIA)
© Kavitsu Group
Our clients:
Walchandnagar industries
Thyssenkrupp
ISGEC
Shrijee process
Suviron equipments
Ulka industries
Wellman industries
West Kenya sugar
Sukari sugar
© Kavitsu Group
Our catalogues:
Our catalogues can be downloaded by clicking the
following link:
Kavitsu Planetary crystallizer Catalogue
Kavitsu Planetary gearbox catalogue
© Kavitsu Group
Our contact details:
Headquarters:
Kavitsu Transmissions Pvt. Ltd.
W-85, Additional MIDC, Satara – 415004
Maharashtra, India
Email: [email protected] / [email protected]
Phone: +91 2162 240804
Fax: +91 2162 240805
Visit us at: http://kavitsu.in
Follow us on LinkedIn: Kavitsu on LinkedIn
Follow us on facebook: Kavitsu on Facebook
Follow our blogs: Kavitsu Blogs
© Kavitsu Group
