In an important digital initiative to make product selection and procurement easier for customers, SEW-EURODRIVE South Africa has launched an online purchasing feature on its website. 

According to Zander Claassens, Training Manager at SEW-EURODRIVE, the portal allows customers to not only order products or parts, but also to find support in the form of documentation and CAD data. To maintain the personal touch, there is even a dedicated person to assist customers with their online requests from 7am to 9pm every day. 

“The online purchasing portal offers users many useful tools and functions, valuable information and practical assistance,” says Claassens. “It is clear that many customers are embracing online procurement platforms, especially since the Covid-19 lockdowns, and we are excited to further enhance our sales and support channels in this way.”

He highlights that the very wide and dynamic range of configurations in SEW-EURODRIVE’s offering demanded that the functions of the shopping cart be specially developed to make it as user-friendly as possible for customers. 

“We have developed four different functions that customers can choose from when adding a product to the shopping cart,” he explains. “The first is through our product configurator, which guides customers in configuring their required equipment – using drop down options from our vast range.”

The next channel would be to use the spare parts or replacement product selection function, where one of two routes can be chosen. In the first, the customer can make use of the SEW-EURODRIVE serial number found on the product nameplate. Entering that serial number is a quick and simple way of request a replacement – and ensuring that the exact configuration is replicated.

“Another route enables customers to find an SEW-EURODRIVE replacement product for a third-party drive – in other words, which is not an SEW-EURODRIVE item,” he said. “Our online tool will not understand the non-SEW-EURODRIVE serial number, of course, but if the specific criteria are supplied, we will know what the customer needs and we will supply.”

Registered customers who have already been trading with SEW-EURODRIVE can also use a third option – a customer transaction overview – to help select what they are looking for. When they log into the online purchasing portal, they will be able to view their history of quotations and orders. This makes it simple to re-order a component that has been purchased before, as they can select the item from a previous transaction or quotation, says Claassens. 

“Lastly, customers can use the drive selection assistant – a smart online tool that guides the user through three simple steps to find the right drive,” he says. “The first step is to select the application, and the second requires more application-related information; the third step then presents the customer with product configurations and suggestions – from which they can choose.”

He reiterates that customers wishing to transact on the portal can find support from a real person behind the portal, who can provide hands-on advice and assistance. Customers can also rest easy that the security of the portal is world class. 

“Our cyber-security is handled by a dedicated IT team in our group headquarters in Germany,” he explains. “Our customer and transaction data are double-encrypted when working online, while the online support is run on hyper-text transfer protocol secure (HTTPS) and is backed up on a geographical redundancy cloud-based system.”

Another security precaution is that online purchasing is not permitted using credit cards, as the company still follows its normal payment protocols with customers once they have placed items in the online shopping cart. 

By simplifying its configuration of components, SEW-EURODRIVE’s modular design delivers the flexibility required to achieve technically unique innovations with parts that are readily available and cost effective. 

“Our modular design allows the same part to be used in different sizes of gearboxes, which facilitates more economic production and less investment in stockholding,” explains Andreas Meid, SEW-EURODRIVE’s Head of Engineering. “By streamlining the number of parts required for a product range, this also allows improved component availability and turnaround time.”

For instance, modularity gives the company’s standard gearboxes a high degree of adaptability, so they can be run in either a vertical or horizontal orientation, says Meid. The customer therefore only needs a single housing in stock as it can be used vertically for an application such as agitation or horizontally for a conveyor system. The majority of the parts are then interchangeable across various applications. 

SEW-EURODRIVE Johannesburg Sales Manager Jayson Jackson points out that most of the gearboxes’ pinion shafts would be suited to the specific gearbox size range, while the gear wheels would have more flexibility to be used in different size gearboxes. 

“This principle has allowed the production of fewer specialised parts while still giving customers access to a wide range of options when developing a solution to their requirements,” says Jackson.

Modularity also has positive impacts for the manufacturing process, which create benefits for customers in the form of cost control and availability of stock. Bruce Farthing, Project Engineer at SEW-EURODRIVE, notes that production of components can be streamlined to improve efficiencies, lead times and masses. 

“This also means we can focus our innovation efforts on a more limited number of parts, making a greater technological impact,” says Farthing. “Moreover, the modular principle makes the assembly of gearboxes simpler across a range of applications.” 

He refers to a recent example of the flexibility of SEW-EURODRIVE products, when girth gear was installed for a mining customer. The girth gear configuration requires two gearboxes – one which is orientated to a left-hand application and the other which is right-handed. 

“This is a critical item of equipment for the plant, so the customer needed on-site spares,” he says. “Due to the modularity of our design, the mine needed to only hold one set of spares as our universal housing range can be adapted to either left-handed or right-handed use.”

Jackson says the SEW-EURODRIVE range holds similar benefits for conveyor applications. Where a customer has multiple conveyors on site, they can minimise the spares inventory as the housing can be inverted to operate on either side of a conveyor. He notes that the modular design also creates useful flexibility in the servicing of gearboxes.

“If a customer calls us with an input shaft assembly is damaged, for instance, we can conduct a pre-assembly in our factory before delivering it to site,” he says. “The mine technician just needs to do a quick changeover instead of having to break the gearbox down to the bearings and gears.”

With its focus on close collaboration with its customers, SEW-EURODRIVE has further raised the technological bar at its DriveAcademy® in recent years. 

Committed to providing strong technical skills support behind its range of products, SEW-EURODRIVE has offered the services of its DriveAcademy® for a decade already. With the move to its new and expanded headquarters at Aeroton in Gauteng, the company has taken its learning facilities to the next level, according to Zander Claassens, Training Manager at SEW-EURODRIVE. 

“Developing skills among our employees and customers has always been a high priority for SEW-EURODRIVE,” says Claassens. “The performance and reliability of our products is directly enhanced when stakeholders understand the technical details and select the right product for the application; this is a cornerstone of our successful business growth.”

In the past 18 months, there has been significant upgrading of resources in the DriveAcademy®, after the company moved into its new Industry 4.0-ready plant. These included state-of-the-art media rooms in the training wing, and the implementation of didactic products and next-generation training equipment. 

Innovation is at the heart of SEW-EURODRIVE’s approach to technology, so it is unsurprising that the company takes a similar line in skills development. Keeping up with new training methods while still remaining adaptable is the only way to stay ahead of the continuous waves of change, he argues. 

“We are constantly updating our training material, and also upgrading our own skills as trainers – adopting new ways of presenting,” he says. “We regularly attend international conferences in person or virtually, to discuss these innovations and share information.”

He highlights that the DriveAcademy® in South Africa is one of the first to adopt and implement augmented reality, with an eye on Industry 4.0 – allowing trainees to learn through holograms and holographic overlays.

“Not only is this a highly effective method, but is something that few people have been exposed to so it generates considerable interest and excitement among trainees,” he says. “Where trainees are exposed to memorable experiences like these, then the retention of information tends to be much greater.”

With its focus on providing solutions, SEW-EURODRIVE leverages its DriveAcademy® by applying relevant knowledge to achieve this goal. Trainees in recent years have come from various sectors including automotive, mining, refining and steel.

“We provide bespoke training for customers based on the products that they use, as well as standard product training courses with an introductory overview in drive engineering,” explains Claassens. “As with our staff, each role within a business has different requirements, so we tailor the training to suit the need.”

He notes that within the global SEW-EURODRIVE family, there are 85 drive technology centres with training departments spread across 54 countries. He emphasises that there is a strong commitment to sharing knowledge for the benefit of the global SEW-EURODRIVE brand. Ensuring high quality of deliverables, all the Drive Academies comply with the SEW-EURODRIVE international corporate standard.

“Due to the technical nature of our product portfolio, all of the training we offer is concluded with theoretical and practical tests, and competency is only declared when certain targets are met,” he explains. “Through this simple but effective process, our staff, agents and customers come to a better comprehension of their chosen topics.”

With well over 100 units already delivered, SEW-EURODRIVE in South Africa is set to continue supplying Ivanhoe Mines’ prestigious Kamoa-Kakula Copper Complex in the Democratic Republic of Congo (DRC), a joint venture with Zijin Mining of China, with a wide range of its X.e-series power packs.

According to Willem Strydom, Business Development at SEW-EURODRIVE, the power packs – which are integrated units comprising gearbox, coupling and motor – will be part of Kamoa-Kakula’s Phase 3 expansion. Since the mine’s first phase of development over five years ago, SEW-EURODRIVE has worked closely with both Ivanhoe Mines and the engineering, procurement and construction (EPC) contractor.

“As in previous phases of the mine’s development, our robust high quality power packs will provide reliable solutions in on-site applications such as conveyors, agitators, and slurry pumps,” says Strydom. “The size range in the order makes use of our wide capability range to provide a total solution, ranging from 55 kW units to 500 kW units.”

The latest order includes several X.e Series power packs for conveyor applications, planetary gearboxes for feeder applications, and spare gearboxes. The equipment will be delivered in staggered shipments this year. While the mine typically undertakes the installation of the equipment, SEW-EURODRIVE sends technical teams to site to check final alignment and overall installation parameters.

The company has expanded its after-sales service teams considerably in recent years, allowing it to support the growing base of equipment throughout Africa. Its projects and engineering teams have also grown – developing a depth of experience to assist customers right from design phase onwards.

Strydom notes that SEW-EURODRIVE has significantly developed its infrastructural foundation in South Africa, and plans to develop a physical representation in over 23 other African countries. As a priority country for the company’s strategy, there is expected to be a representative in place in the DRC in 2023, he explains. Field service teams from South Africa are frequently at Kamoa-Kakula to assist with servicing of the existing power packs operating on the site.

“Our local assembly capability in our new facility in Johannesburg – combined with our ability to source from the group’s other global operations – has allowed us to meet the tight delivery deadlines for this substantial order of equipment,” he says. “Our global footprint and production capacity mean that we can deliver faster than most players in our field, and this is often an important factor for our market.”

While the company previously imported the larger X.e Industrial gearboxes from Germany, it is now able to assemble these in the new South African facilities. As part of its service, SEW-EURODRIVE will also handle the logistics of getting this large volume of equipment to site. The company’s training centre – the Drive Academy – in Johannesburg has also made a valuable contribution by providing training on the equipment and its maintenance.

In this project, the tropical climate was another important factor in the customer’s design requirements. This required the inclusion of certain cooling and paint specifications in the contract. SEW-EURODRIVE Head of Engineering Andreas Meid explains that special breathers were part of the design in response to high humidity levels – and served to ensure no moisture in the gearboxes. In outdoor applications where sun exposure was high, covers were also included to reduce heat build-up. Cooling fans were also optimised in certain cases to ensure optimal performance.

He highlights that Kamoa-Kakula is one of many projects in Africa to request the installation of monitoring equipment on the power packs. This facilitates real-time monitoring, using specialised sensors to measure key indicators like vibration and temperature from anywhere in the world.

“This allows the operation to monitor the equipment remotely, receiving early warnings of any issues in performance,” says Meid. “Responding timeously to this information can prevent serious damage and avoid unplanned downtime.”

As a preferred supplier, SEW-EURODRIVE first delivered a multitude of X.e Series power packs between 2019 and 2021 for the mine’s initial development phase. Motors ranging in motor from 7, 5 kW to 500 kW as well as planetary gearboxes were supplied during this time for feeder applications, together with several spare gearboxes.

For Kamoa-Kakula’s Phase 2 expansion, which doubled the concentrator plant capacity, SEW-EURODRIVE supplied many standard X.e Series power packs for the conveyors as well as planetary gearboxes for the feeders.

Well known for its drive technology, SEW-EURODRIVE partners with customers to design and implement automation projects for their plants, factories and warehouses – using its powerful Maxolution® offering.

According to Werner Engelbrecht, Works Manager Mechatronics at SEW-EURODRIVE, this process is focused on combining all aspects of production including hardware and software. Rather than a customer having to develop their own software infrastructure from scratch, says Engelbrecht, Maxolution® has its own pre-defined application modules that have been developed from years of experience in the field.

“With our specialised software, we can simulate material flow in industrial systems, helping customers to achieve greater efficiency through multiple integrations of systems,” he says. “The Maxolution® portfolio allows applications in the customer’s facility to be incorporated into a single network.”

This creates the foundation for a complete system to work in synergy; it also opens the door to integrate new systems and to allow existing systems to adapt to product changes. Maxolution® can offer cost effective adaptability for product variations in a production line due to its easily programmable application modules.

The system has already been installed to help automate the factories of leading South African car manufacturers. However, he argues that Maxolution® has significant potential in other local sectors, helping to raise efficiencies, productivity and output.

“With our experience and the proven technology, we can use Maxolution® to implement automation plans cost-effectively and quickly,” he says. “These solutions also save energy through the use of energy management systems and energy efficient IE4 and IE5 mechatronic decentralised solutions and motors.”

He highlights that the Maxolution® offering is an important way that SEW-EURODRIVE differentiates itself as not only an equipment supplier, but as a partner in project planning, commissioning, after-sales service and support. Customers can even enrol staff for training at SEW-EURODRIVE’s state-of-the-art Drive Academy near Johannesburg.

Building on the success of its tried-and-tested X.e series of high-performance industrial gear units and gearmotors, SEW-EURODRIVE has launched a new X.e series agitator gear design.

This agitator gear unit boasts high permissible forces and bending moments alongside its operational reliability – making it ideal for all high-performance agitators and mixers. According to SEW-EURODRIVE’s Head of Business Development Engineering, Andreas Meid, the agitator gear design expands the company’s portfolio to include more application gear units designed for specific uses.

“Agitator gear units are used in various industries across Africa including chemical, pharmaceutical, food and beverage, and water and wastewater treatment – for mixing and blending liquids and other materials,” says Meid. “The X.e-series agitator gear units can be used wherever high power ratings are required for stirring and mixing liquid or paste-type materials.”

SEW-EURODRIVE’s X.e series features a modular design for flexible customisation, and includes innovative motor and gear unit technology that ensures high efficiency and long service life. As part of this range, the SEW-EURODRIVE X.e agitator gear unit is designed to provide reliable and efficient operation in these demanding applications.

Meid highlights that the ‘digital twin’ concept was applied throughout the design process for the X.e-series agitator gear unit, making it possible to simulate and optimise the mechanical components and oil flow in virtual reality.

“The application-specific rolling bearing concept – with a large bearing spacing and its rigidity optimised agitator housing – allows the unit to absorb the strong forces and bending moments that typically occur in agitation and mixing processes,” he explains. “Depending on the particular load scenario, there are three load-specific rolling bearing variants available for each size.”

The X.e agitator gear unit’s advanced gear technology, which includes helical and bevel-helical gearing, provides high torque transmission with low noise and vibration. This ensures smooth and efficient operation, even in high load applications.

“Among the innovative design elements of the gear unit is an oil expansion chamber to compensate for temperature variations,” he says. “It also features a labyrinth sealing system to prevent contamination and reduce the risk of oil leakage.”

The units are available in three sizes, for a torque range of 117 to 217 kNm. As a three-stage or four-stage helical gear unit, it also covers gear ratios ranging from 20 to 400.

Recently installed in a power station, 24 of SEW-EURODRIVE’s MACC-Series two-stage gear units for air cooled condensers are ensuring adequate air movement to cool circulating water so that power generation can continue.

This cooling function had become a challenge for the power station when the previously installed competitor products had repeatedly failed unexpectedly. SEW-EURODRIVE had installed these MACC units over the past few years, and their reliable operation has led to a request to supply several additional units. According to SEW-EURODRIVE Business Development Representative Quintin Bianchina, the design is specific to this demanding application.

“Comprising a gearbox and long output shaft that attaches to a fan via a hub, these MACC units also boast a thicker, more rigid cast iron housing than a standard gearbox,” explains Bianchina. “The radial and axial loads transmitted by the fan are substantial, requiring a suitable design that will withstand these forces.”

With the fan in operation, there is both upward and downward thrust as well as forces to the left and right. The flat topography and climatic conditions around the power station also exacerbate the situation, especially on hot days when air moves rapidly up the cooling towers. The gearbox, bearings and shaft must be designed and manufactured to accommodate these forces while continuing to operate reliably.

“This application is, in fact, so challenging that the customers’ existing equipment was not coping with the demands,” he says. “We were able to offer our world class engineering solutions to develop the MACC09 model – the largest version in this range – which has proved fit for purpose under these arduous conditions.”

The noise levels are an additional factor in this application, and the quiet MACC units ensure that they do not exceed maximum limits; the customer monitors the noise to check compliance. Heat build-up in the gearbox must also be dissipated, so the design includes cooling ribs to increase the surface area. This design enhances the cooling significantly on the gear units. SEW-EURODRIVE also offers a low noise axial cooling fan as an option, for enhanced thermal improvements.

Another vital aspect of the SEW-EURODRIVE’s MACC’s features is the maintenance safety brake on the high speed input section of the gearbox. This can be applied to bring the fan safely and easily to a standstill under wind milling conditions when maintenance is required. 

“Due to their size, these fans do not otherwise stop turning once they start – due to the natural upward airflow into the cooling tower,” he says. 

Since SEW-EURODRIVE has recently built a new and expanded facility at Aeroton in Gauteng, the assembly of these MACC units can be done locally. Enlarged stockholdings of components means that the turnaround time will be drastically reduced. 

“Rather than the usual 30+ weeks to import this equipment, we expect to assemble and deliver these in batches within 8 to 12 weeks,” says Bianchina. The MACC series is designed and tested by SEW-EURODRIVE’s centre of excellence for these products in Finland.

As its expansion into Africa gathers pace, SEW-EURODRIVE South Africa is getting closer to customers and building stronger direct partnerships – to push modernisation and efficiency.

“It just makes sense for our customers to have direct access to the OEM,” says Jonathan McKey, National Sales and Marketing Manager at SEW-EURODRIVE. “This is particularly relevant in Africa, where distances to sites can be lengthy and the infrastructure is often limited.”

He points out that SEW-EURODRIVE in South Africa is already serving large multinational corporations around Africa who have global agreements with SEW-EURODRIVE at head office level. These customers are active in industries such as food and beverage, automotive, mining and specialised machinery. 

“Big international customers want to know that all their subsidiaries around the world can receive the same high quality of service for their SEW-EURODRIVE equipment,” he says. “The same applies for any size of customer; Africa is now demanding higher levels of technical support, especially in those countries experiencing economic growth and technological advancement.” 

He notes that governments are also encouraging the global private sector to have a local presence in African countries and SEW-EURODRIVE is responding to that call. This fits well with the SEW-EURODRIVE culture of being close to customers wherever they are, so that the service response can be quicker and more effective. 

“We are very serious about implementing this culture, and we are well positioned to drive our expansion initiative into Africa,” he says. SEW-EURODRIVE has already placed staff in Kenya and Zambia and is planning to establish a presence in three more African countries during 2023. 

Placing its own people on the ground around Africa will enhance to value to customers, says McKey, especially with SEW-EURODRIVE’s continuous development and ‘zero complacency’ approach to innovation. 

“Our research and development cover a wide range of fields that can benefit customers – from gearing topography to specialised gearbox oils,” he says. “With more sophisticated tools to analyse our own products, we have been able to offer customers even higher reliability as well as improvements in aspects such as torque demand.”

This progress has been enhanced by a strong digital offering, which Africa is already well placed to leverage. SEW-EURODRIVE has some of the most advanced technology for monitoring the condition of drives, paving the way for customers to apply more proactive maintenance. Raymond Obermeyer, Managing Director of SEW-EURODRIVE South Africa, highlights that Africa is generally well advanced in digital communication. 

“Access to the cellular network makes everything possible, from selecting and buying gearboxes to monitoring and analysing their performance remotely,” says Obermeyer. Indeed, the range of SEW-EURODRIVE equipment has been designed to use multiple communication methods, and to communicate to every device from SCADA systems to computers and mobile phones. Systems like DriveRadar® can therefore be installed on a product and monitored from anywhere in the world where there is a data signal.

Given this depth of technology and innovation, McKey emphasises that direct contact with customers is preferable to working through a ‘middle man’. Through its extensive and ongoing training efforts, the company upskills its own employees and customer staff, to fully understand both the operation and the potential of its technology. 

“We have invested in our in-house Drive Academy for precisely this purpose which can provide skills development in-person at our Johannesburg facility or remotely,” he says. “This creates a symbiotic relationship with customers, where we support each other in the trend towards modernisation.”

This applies to the company’s modular ranges as well as to its purpose-built products – such as the air-cooled condenser (ACC) solutions. Greater in-house expertise also ensures that constant advancements are brought to customers’ attention. A recent example of this was the evolution of the robust X series industrial gear units to the state-of-the-art Generation X.e units, delivering new possibilities in performance, safety and efficiency.

Obermeyer points out that the most advanced SEW-EURODRIVE products are already found all over Africa, showing how the continent has embraced technology. The company’s expectation is that this equipment is supplied and maintained to the same highest standards anywhere in the world. The growing footprint of SEW-EURODRIVE branches across Africa will ensure that this is achieved, he says.