A CONVEYOR UPGRADE THAT INCREASED UPTIME & LOWERED COSTS
EXPERIENCE THE DIFFERENCE YOURSELF
case study:
with poly chain gt carbon
An international shipping carrier that processes approximately nine million packages daily across North America was facing frequent roller chain failures at a distribution facility in Illinois. The resulting downtime and maintenance costs were impacting productivity and operational efficiency.
To address the issue, Gates helped convert the facility’s conveyor drives from roller chain to Poly Chain GT Carbon synchronous belt drives, significantly increasing uptime, reducing maintenance, and delivering millions of dollars in long-term savings.
End Market:
Application:
Original Parts:
Solution:
Intralogistics
Horizontal Distribution Conveyor
80# and 100# Roller Chain
Gates Poly Chain GT Carbon Synchronous Belt
MEASURABLE SAVINGS
The distribution hub experienced an average savings of $44,300 per drive by the third year after conversion, for a total savings of $3,500,000.
The reduction in roller chain replacements and related maintenance activities freed personnel to focus on higher value operational priorities.
Poly Chain GT Carbon belts achieved an average operating life of three years, delivering approximately twelve times the service life of the roller chains previously installed.
$3.5M
211
12X
problem
At the Illinois distribution facility, conveyor systems play a critical role in keeping thousands of packages moving through the operation each day.
The facility's horizontal distribution conveyor system was experiencing chronic reliability issues due to undersized gearboxes that placed excessive stress on the roller chain drives. As a result, maintenance teams were forced to replace chains on a weekly basis to keep operations running. These frequent replacements created costly downtime, increased labor requirements, and reduced overall productivity.
The ongoing cycle of maintenance and repairs made it difficult for the facility to meet performance targets and maximize throughput.
In a high-volume distribution environment where every minute of downtime directly impacts operational efficiency, facility leadership recognized the need for a more durable, low-maintenance solution capable of supporting long-term performance and reliability.
Problem
Solution
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Toggle below to read about our customer's initial problem and how Gates solved it.
To break the cycle of recurring maintenance and costly downtime, Gates partnered with the facility's maintenance team to evaluate a more reliable alternative to roller chain drives. The team selected Poly Chain GT Carbon synchronous belt drives and began a phased conversion of the conveyor system. Over the course of eight months, 79 conveyor drives were upgraded, significantly reducing maintenance requirements, while increasing uptime and throughput capacity.
The results quickly validated the investment. Poly Chain GT Carbon belts delivered an average service life of three years, approximately 12 times longer than the roller chains they replaced, eliminating the need for frequent chain replacements and the labor-intensive maintenance associated with them. The facility achieved full return on investment in just 15 months, and the success of the project led to additional conversions at several neighboring distribution hubs to improve their reliability and reduce operating costs.
solution
high performance, low maintenance
poly chain gt carbon:
In distribution and material handling environments, the true cost of a drive system extends far beyond the initial purchase price. Maintenance labor, downtime, replacement components, productivity losses, and energy consumption all contribute to total cost of ownership.
Gates Poly Chain synchronous belts are engineered for applications that demand consistent performance over long service life. They are built to operate reliably under high loads and extended center distances while maintaining stable power transmission and system efficiency. At the core of our design are patented carbon fiber tensile cords that increase horsepower capability without adding bulk. This allows for a compact, flexible belt that supports backside idlers and resists stretch over time.
Connect with a Gates product expert today to discover how we can help you accelerate your return on investment and lower your total cost of ownership!
Carbon tensile cord provides high power density for robust load carrying capacity in a compact package, while reducing stretch
No lubrication or retensioning eliminates most maintenance costs
3x longer lifespan than roller chain for a total lower cost of ownership
ready to experience the gates difference for yourself?
Take advantage of our expertise! If you're interested in learning how a synchronous belt system can help your facility save on maintenance and operational costs while increasing your uptime, we can help.
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in third-year savings
annual maintenance hours saved
longer drive lifespan
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