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Super Premium Efficiency for food processing applications

17 July 2015

Bauer Gear Motor developed the world's first modular, stainless steel, IE4 super premium efficiency geared motor using permanent magnetic synchronous motor (PMSM) and aseptic drive technologies, combineing the benefits of both and is ideal for use in hygiene critical applications such as food processing and packaging.

Part of Altra Industrial Motion, Bauer’s distinguished history in designing geared motors started in 1927 and since then the accumulated knowledge and expertise has led to Bauer becoming a pioneer in geared motor solutions. This includes more recent developments in electric motor design that have delivered levels of efficiency that exceed current European legislation.

A continual belief in innovative design and a desire to work closely with customers to increase efficiency and productivity has led to Bauer becoming a leading manufacturer with the ability to deliver the requirements of specialist applications.

In today’s market, energy efficiency has to be one of the key determining factors when specifying geared motor solutions. Long term energy prices are likely to increase, so it is important that a drive’s lifelong running costs are considered; rather than simply the cost of procurement. Bauer has developed the new stainless steel gear motor to offer those customers with applications in hygienic areas, the very best in terms of efficiency and reliability.

The special hygiene demands of the food and beverage industries demand specialist components that typically have to be specified to withstand the regular cleaning regimes to guarantee clean operation without risk of contamination.

Bauer’s stainless steel, PMSM synchronous motors are designed for this environment and also offer considerably improved efficiency when compared to induction motors, even under partial load conditions. In real life application examples they have been shown to offer energy savings of over 40% when compared to a standard, asynchronous motor. 

Bauer has invested a considerable amount of design and development time into ensuring that its PMSM motor and drive packages deliver high efficiency performance on partial loads, a criticism that has been levelled at other Permanent Magnet designs as the efficiency can drop-off sharply outside the ideal operating speed and load. Bauer’s PMSM motors maintain higher efficiency levels, even under partial load where a 30% energy saving is still possible, compared to asynchronous designs.

In this latest offering, the designers have brought together a number of features and specifications to deliver excellent energy efficiency while still meeting the required hygiene standards. The use of embedded permanent magnets reduces heat losses from the motor by 100% which supports the removal of the fan and cooling ribs, as seen in the asceptic range. This enables the outer casing to be completely smooth and a non-drive end that is sealed.

This innovative design eliminates any dirt traps on the motor casing and also guards against possible contamination caused by air movement from a cooling fan. The modular geared motor is also designed with surfaces that slope by at least 3° to prevent the formation of deposits of dust and debris whilst also allowing the run-off of cleaning agents and water. 

The stainless steel construction provides excellent corrosion resistance and also eliminates the risk of the hygiene rating becoming compromised in the event of an impact, which can happen with painted surfaces. Furthermore, the design is well suited to prolonged periods of use in heavy washdown environments, making it the perfect addition to Bauer's range of super premium efficiency motors for the food & beverage industry.

Bauer’s understanding of the needs and requirements of this industry, allows it to design complimentary products, such as CleanConnect, which provides market leading cable connections in hygienic areas. This brings together the IP67 rating of many connectors with the corrosion resistance and durability of stainless steel. 

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