(479) 358-1173

How the World’s Largest Poultry Producer Cut Belt Conveying Costs 43%

Belt conveyors are largely considered a necessary evil due to the fact that the motor-driven systems can eat up as much as 50% of a facility’s power. Due to this fact, many factories are continually looking for ways to improve efficiency and lower their monthly electric bill.

One of such factories happens to be the largest poultry producer in the world, who we’ll refer to as “Company X”. In an effort to cut costs, Company X decided to install one of the popular direct drive motors on the market today.

For those unfamiliar with the direct-drive concept, the motor operates by shifting the external gear train into the pulley itself. While this does present several benefits such as space savings, food safety, and yes, even efficiency, it still has several rotating components.

Direct Drive Motors Move the Gear Train from Outside the Motor to Inside the Pulley

It’s worth noting that the more rotating components that you have, the more loss of power you will have. Energy passes through each rotating component. So, while the initial direct drive motor did help improve efficiency, there was still room for improvement.

Enter the Magnetic, Direct-Drive technology of One Motion. Rather than simply moving the external gear train inside of the pulley, One Motion products use magnets to push each other around to create rotation.

One Motion Direct Drive Products Use Magnets to Push Against Each to Create Rotation

The magnets rest inside the pulley itself. This means there is only ONE transfer of energy. 

With this in mind, Company X decided to replace their current direct drive motors with One Motion pulleys. Considering their current direct drive motors had already made an improvement in efficiency, this made for an exciting opportunity to really put the efficiency of One Motion products to the test!

Time For Geek Speak

Here’s where we geek out a bit and look at some numbers. For this to be a true test, we needed to measure the power going into the panel that was running the motors, both before and after the One Motion install.

The reason for checking the input power going into the panel is that these will be the numbers that ultimately have an effect on your electric bill. Checking the power from the panel to the motor would have other power factors that could skew the test results.

The current on the pre-installed wires were 1.1, 1.1, and 1.3 amps. That is an average of 1.16 amps.

Once the Powered Pulleys were in place, the current on each wire read 0.6, 0.6, and 0.8 amps, which equates to 0.66667 amps. The resulting difference was a reduction of about 44%!  

The equation for determining costs looks like this:

P(W) = I(A) × V(V)

Pre One Motion Install:

1.2 (amps) x 480 (voltage) = 576 Watts

When converted to kilowatts, it would be 0.5760.

That equates to 13.824 kWh in a day (24 hours).

Based off of $0.12 per kWh, the resulting monthly cost would be 49.77 and annual cost 597.20.

Post One Motion Install:

0.68 (amps) x 480 (voltage) = 326.4 Watts

Converted to kilowatts, it would be 0.3264

That equates to 7.8336 kWh used in a day (24 hours).

Based off of $0.12 per kWh, the resulting monthly cost would now be 28.20 and annual cost $338.41

That’s an overall savings of 43% ! Also, keep in mind the numbers above are based off of just one motor. Please feel free to reference this calculator to play around with the math yourself!


The reason for measuring the wires going into the panel is that the input power is isolated from other power factor issues going into the motor.

Measuring the amps in this way creates a clear picture of the actual power being spent to power the conveyor.

The improvement in efficiency should continue to be seen as the future installs take place.

Are you serious about improving efficiency and cutting costs at your factory? If so give us a call at (479) 696-9089 today!