LEADING engineering specialists BMG plays a critical role in the sugar sector, not only during the operational period of sugar production, but also in off-crop seasons, when maintenance and refurbishment on sugar farms and at mills is essential.
The team works closely with sugar farmers and engineers at mills and provides engineering components and support services to enhance production efficiencies, minimise downtime and extend service life of equipment.
BMG’s power transmission division supplies and supports a wide-range of products, which are selected for dependable performance in demanding conditions. These components include carrier and diffuser chains, knife and shredder bearing housings, custom sprockets and gear couplings, as well as steam gaskets, heat exchangers and hydraulic tools. Diffuser and mill gearboxes, in addition to mill lubrication and hydraulic systems, form a critical part of this range.
“BMG boasts a depth of experience in the sugar sector, through the provision over decades of power transmission solutions that ensure high productivity in cane fields and during processing and refinement,” said Gavin Kirstein, business unit manager of BMG’s power transmission division.
An important service to the sugar sector is the chain refurbishment facility in Durban, where chains are stripped, inspected and re-assembled, using new components where necessary. This refurbishment service is often carried out under strict time restrictions, which requires advanced planning.
“Analysis of chain failures is also conducted at this facility. Specialists are able to advise customers on the expected remaining wear-life of a chain and on what improvements need to be introduced to their systems,” said Kirstein.
Other specialist services in the sugar sector include bearing and gearbox inspection, bearing and chain refurbishment, large size bearing assembly, alignment and balancing, as well as customised product design. BMG also offers a troubleshooting and maintenance service, condition monitoring and training.
Tsubaki chains
Tsubaki high performance chains – key components in BMG’s power transmission division – are well-suited for harsh conditions in sugar processing and production, offering enhanced strength and reliability, a cleaner environment and extended operating life.
“BMG specialists are able to provide solutions for any problems customers face when using conveyor chain. We can adapt the materials used and even the heat treatment of a chain’s components to match the specific application and operating environment – whether in the sugarcane field, or in the mill or refinery,” said Marthinus Janse van Rensburg, national product manager at Tsubaki, BMG.
A range of chains with stainless steel components are also on offer to protect against corrosion, which is especially problematic on bagasse carriers and elevators. Stainless steel components can be heat treated to provide wear and corrosion resistance, as well as additional strength.
Tsubaki products are suitable for the sugar industry, and encompass cane harvester chains manufactured at an ISO-certified facility, in-line with Tsubaki’s exacting specifications. All components are shot-peened and the chain is also statically pre-loaded for enhanced wear life in the harsh conditions of cane fields.
Tsubaki manufactures a wide-range of mud conveyor chains, designed especially for damp conditions, which are fitted with stainless steel pins and bushes for protection against corrosion and wear.
BMG also supplies a wide-range of robust cane carrier chain that provides excellent durability and wear resistance during operation in demanding conditions in sugar mills. Cane bagasse carrier chains with outboard rollers are available too.
This chain is designed to maintain a thin layer of lubrication on the bearing surface, extending service life of the system. The convenient location of outboard rollers enables simplified maintenance and easy replacement of components, without having to dismantle the entire system, and eliminates costly downtime.
BMG’s Tsubaki RF Series intermediate carrier chains are manufactured from durable materials, with stainless steel grade for the pin and bush to protect against corrosion and wear. The pin and bush areas are also lubricated with MoS2 grease during assembly and since the chain is not normally lubricated during operation this grease is baked on in certain areas to provide enhanced lubrication functions.
Tsubaki diffuser and cast dog bone link type chains, with special design features to withstand operation in harsh conditions, also have stainless steel pins and bushes for enhanced protection against corrosion and wear.
The most critical chain application in sugar processing is the bagasse reclaimer, which powers the mill. Tsubaki has made a substantial investment in market research and field testing to develop a robust bagasse reclaimer chain, with a grade of stainless steel that has the highest combined levels of corrosion resistance, strength and wear properties. In addition, induction-hardened pins offer extended service life. Pin and bushing areas are lubricated with MoS2 grease during assembly and have baked-on grease in critical areas. Attachments are robotically welded to the chain, to ensure the strongest weld penetration.
Field service maintenance
The BMG team attends to breakdowns in sugar mills and refineries and meets tight time-frames to manufacture replacement components. Recent field service maintenance projects during off-crop seasons involved a turnkey in-situ replacement of diffuser head shaft bearings and the complete refurbishment of the multi-misalignment couplings driving each end of the head shaft. This project also involved the installation of new bearings and adaptor sleeves, as well as new keys and connector arms for the couplings.
BMG’s specialist services to the local sugar sector are underpinned by a broad range of quality-branded engineering components, a technically competent team and a 24-hour support service.
