Sugar Industry Success Story - Usina Ferrari

Sugar industry reference, sugar industry customer
Marginal Column

Tough application

The need to maximize uptime and optimize extraction.

Ingenious solution

The ability to drive each roller individually means much for the productivity, as the friction can be perfectly adjusted to optimize extraction.

Sugar industry reference, sugar industry customer

Exactly

“We were already pleased with the excellent operating performance, which provides us with high crushing flexibility and quality,” says Fantinatti. “So we were very pleased to see that the motors’ durability also meets our high expectations.” / Paulo Fantinatti

Solved with

The Usina Ferrari mill has types of Hägglunds motors: four Hägglunds MB2400 on the first 84” inch crusher and twelve Hägglunds MB1600 on the additional 78” crushers.

Content

Compact and reliable hydraulic drive system

After years of crushing cane,
Hägglunds motors show no wear

Brazilian sugar producer Usina Ferrari relies heavily on the Hägglunds hydraulic direct drives that crush its cane. After six years in operation, these proven solutions from Bosch Rexroth remain unaffected by the tough job they perform.

 
 

Usina Ferrari is one of several sugar producers in the municipality of Pirassununga, located in the Brazilian state of São Paulo. The municipality derives much of its income from sugar production, and Usina Ferrari is keen to find solutions that maximize output and uptime.

It was for this reason that Usina Ferrari installed a new milling tandem in 2008. Manufactured by Dedini with a crushing capacity of 640 tons per hour, the mill has four three-roll crushers, all driven by Hägglunds hydraulic motors from Bosch Rexroth.

“Each roller is individually driven, with two motors on the upper roller, one on the sugar cane roller and one on the bagasse roller,” says Paulo Fantinatti, who manages Usina Ferrari together with Hênio Respondovesk. “We appreciate the compactness of the Hägglunds motors, which are operated directly at low speed without any speed reducer. And we’ve been impressed by the high torque they deliver at any speed.”

The ability to drive each roller individually means much for Usina Ferrari’s productivity, as the friction can be perfectly adjusted to optimize extraction. In addition, the drives have provided considerable peace of mind, requiring virtually no maintenance attention.

“In the six harvests after starting up the mill, we had it operating for about 30,000 hours and crushing around 15 million tons of sugar cane,” says Fantinatti. “During that time, the motors required no intervention whatsoever.” This is hardly surprising, since Hägglunds motors have a fully enclosed radial piston design, ideal for harsh industrial environments. But after such a long period of continuous operation, it was decided to perform a detailed inspection.

In January 2015, after six years of tough operation, one of the Hägglunds MB motors was removed for inspection at a Bosch Rexroth workshop. “The results were simply amazing,” says Edmundo Neto, the Bosch Rexroth technical expert who performed the motor analysis. “The contact surfaces of the transmission elements – such as the cam rings, rollers, pistons, guide plates and bearings – were still as good as new.”

Usina Ferrari’s managers, who followed the inspection closely, were also satisfied with the results. “We were already pleased with the excellent operating performance, which provides us with high crushing flexibility and quality,” says Fantinatti. “So we were very pleased to see that the motors’ durability also meets our high expectations.”