Sugar Industry Success Story - Rajawali PT

Sugar industry reference, sugar industry customer
Marginal Column

Tough application

Sugar presses operating continuously in demanding conditions with shock loads, high temperatures and flushing.

Ingenious solution

A rugged and reliable solution in a compact design offering a wide range of operations.

Sugar industry reference, sugar industry customer

Exactly

"The Hägglunds direct drive system has a wider range of operation with good results compare to traditional drive" says Mr Hari Widodo Development / Technical manager PT. PG. Rajawali 1

Solved with

Hägglunds direct drive systems including:

  • Four 3000 series Hägglunds CBM motors, torque arms and shaft adapters
  • Two Hägglunds DUe drive unit
  • Spider control system
  • Piping
Content

Compact and reliable hydraulic drive system

Investment safeguards production at Indonesian sugar mill

A state-owned conglomerate, PT Rajawali Nusantara Indonesia (RNI), has placed an order for a hydraulic direct drive system with Bosch Rexroth based on four Hägglunds CBM motors. The system is intended to safeguard production at the Krebet Baru 1 sugar mill on Java.

 
 

“The sugar mill season lasts six to seven months each year. In that period our customers must be able to rely on production working around the clock – regardless of the supply rate and line speed,” says Tomas Kallin, Industry Sector Manager for Sugar at Bosch Rexroth.

RNI has more than 7,000 employees, around 20 affiliates and subsidiaries, and 18 production units, 10 of which are sugar mills. The Krebet Baru 1 mill is located in Malang, the second largest city in eastern Java, which is enjoying steady economic growth.

The Krebet Baru 1 mill requires reliable and versatile drives for its sugar presses, and has in the past had challenges with failures of gearbox solutions. Inside the mill the sugar cane is crushed and washed to extract sugar in a five-stage process, rather like a three-roll wringer. The conditions are demanding, involving shock loads, high temperatures and flushing with water several times a day to wash away dust.

Reliability a key priority

Agricultural production is weather-dependent and if the plantations are wet Krebet Baru does not get any raw material. The sugar cane cannot be stored either since it spoils within 24 to 36 hours of harvesting. To maintain continuous production the speed of the sugar mill is reduced so that it runs slower. The CBM will keep the torque ensuring a good extraction.

“The Hägglunds direct drive system has a wider range of operation with good results compared to traditional drive” says Mr Hari Widodo Development / Technical manager PT. PG. Rajawali. “The thousands of farmers who deliver the raw material depend on the sugar mill to be working on the day they bring their harvest in,” says Tomas Kallin. Continuous operation of sugar mill machinery is also essential because the waste product, bagasse, is also then in turn burned to produce steam and generate electricity for the mill. Any stoppage in production means a delay in firing up the system again.

Hägglunds drives opened the door

Hägglunds has been supplying products to the sugar industry for almost 30 years and offers the right capacity for this type of application.

RNI already had good experience with Hägglunds MB motors and was therefore interested in their successor, Hägglunds CBM motors, which are at least as powerful but also considerably smaller, lighter and have an even longer life time. The local Bosch Rexroth sales representatives, Lai Keng Onn (Regional Center of Competence for Southeast Asia) and The Swi Swi (Sales & Project Manager, Indonesia), had also previously worked at Hägglunds Drives sales office in the region and were familiar faces for the customer. As a result Bosch Rexroth was added to RNI’s approved supplier list and given the opportunity to tender for contracts. A deal was signed in June, and Bosch Rexroth Indonesia now has its first order from RNI.

The order is an Independent Roll Drive system. The Hägglunds direct drive system comprises four 3000 series Hägglunds CBM motors, torque arms, shaft adapters and two Hägglunds Drive Units (with SP500 pumps and 250 kW electric motors). The order also includes piping, Hägglunds control system, installation, tools and supervision of installation and commissioning. The drive system was installed in April 2014.

„We feel very confident that we have chosen a great solution. We feel very assured also from the well working reference installations that we have seen, says Mr Ali Ansori, Milling Manager at PT Rajawali.

Small but powerful

Bosch Rexroth’s Sector Manager sums up the benefits of the system as follows:

“The compact CBM motors save space and create a system that can easily be reconfigured to suit capacity requirements without needing to halt production. The drives put less stress on shafts and bearings during shock loading. Thanks to their high torque the motors are also able to squeeze more sugar out of the cane and continue driving hard even if someone feeds so much cane into the line that it slows down to almost a standstill. If that’s not enough, the drive can also be reversed so that the trapped material can be removed.”

Another feature the customer sees as a benefit is having a supplier who takes total responsibility for a complete and fully installed system, with local access to service personnel.

„The cooperation with Bosch Rexroth has worked very well. I‘m happy and pleased that the service from Bosch Rexroth is so good.“ says Mr Ali Ansori.

“We naturally see big potential in being a long-term partner to the customer, especially since we can also offer service and support on Java. Krebet Baru is only an hour’s flight away. Our personnel speak the same language as the customer and have completed an extensive training program on Hägglunds’ products and receive regular additional training.”

“This means we can meet our customer’s requirement to be ready when the busy harvest season starts up again,” concludes Tomas Kallin.