An aggregate mining operation, one of the largest quarries in the southeastern United States, produces granite products that serve major infrastructure and construction projects. The facility processes seven different types of aggregate material, with the primary focus being producing granite stone.

Mission-critical to the facility, belt conveyors move granite material to different stages of processing—from crushing to screening, storage, and loading—and rely on gear reducers to control the application’s speed for safe, smooth operation.

Requiring frequent V-belt tension adjustments and replacement of a complete unit on average every 3 months, the existing competitive belt-driven reducers on belt conveyors throughout the facility created significant unplanned downtime due to a shortage of adequately skilled maintenance staff. With downtime costing up to $18,000 per hour, plant management sought a more maintenance-friendly, reliable solution to address their maintenance workforce constraints, improve system efficiency, and maximize operation uptime.