SmartFlow™ Cotton Gin Hydraulic Technology


SmartFlow™ Pumps: More Speed, Fewer Problems

One thing that we admire about cotton gin managers is that they endeavor to be economical and prudent stewards of their assets.  They work hard to keep equipment in working order for as long as possible.  This is certainly the case when it comes to gin press pumps.  Since 1944, we have partnered with gins to restore hydraulic units to "like-new" condition.

At some point, however, your customers will be better served by truly new hydraulic units.

Here's why.  When you don't take advantage of gains in productivity you're leaving money on the table and falling behind your competition. 

Lubbock Electric's SmartFlow™ design for cotton gin hydraulic power units utilizes advanced hydraulic technology to boost ginning speed and eliminate common hydraulic problems.  Cotton gins that have replaced their decades-old hydraulic equimpent with SmartFlow™ pumping units have experienced significant production gains.  Let's examine what SmartFlow™ can do for your business.

 

Key FeaturesClient Success StoryDetailed SpecificationsRequest a Quote

 


Key Features

► Unique "Baffling" Technology Filters Out Contaminants

Oil contamination is one of the chief causes of hydraulic failures.  Foreign contaminants in hydraulic fluid impede operational efficiency, cause corrosion, change the viscosity of the fluid, and accelerate wear and tear.  SmartFlow™ is designed to protect your equipment and maintain uptime.  In addition to hydraulic filters, SmartFlow™ uses a uniquely engineered baffling plate that filters contaminants inside the tank.

► Flooded Suction Prevents Cavitation

Another common cause of hydraulic breakdowns is cavitation.  Pump cavitation is the formation of vapor cavities (or "bubbles") that occurs when the pressure in the pump inlet drops below the pressure of the liquid.  To save space in a cotton gin, many traditional press pump units utilize a top-mounted configuration in which the motors and pumps are placed on top of the tank.  However, this design is prone to cavitation because the pump has to work against gravity to pull oil up.

SmartFlow™ involves a flooded suction (also called "flodded inlet") design.  Pumps are placed below the minimum oil level, and gravity assists in creating pressure into the pump and suction line.  This design makes cavitation nearly impossible.

Flooded Suction

► Three-stage Vane Pumps Allow For More Oil and More Speed

To be competitive, cotton gins need to gin more cotton in less time.  This is why SmartFlow™ uses three-stage vane pumps.  The increase in size from a two-stage and a three-stage pump allows for a greater volume of hydraulic fluid in the pump and higher pressure.

► Temperature Controllers and Oil Coolers Maintain Proper Oil Temperatures

Looking to gin more bales per hour?  That's what SmartFlow™ is designed for!  However, greater speed means that more heat will be generated.  Fluid temperatures above 180°F (82°C) can damage seals, impair system components, and accelerate degradation of the fluid.  We have incorporated advanced temperature controllers and powerful oil coolers into our SmartFlow™ design so that you can protect your hydraulic lines while increasing speed.

Temperature Controllers

► Flexible Hoses Simplify Replacing Pumps and Reduce Vibration

SmartFlow™ uses hydraulic hoses instead of pipe to connect pumps to the hydraulic circuit.  This makes it much easier and quicker for repair technicians to replace and repair pumps and motors.  This also reduces the cost of service calls and decreases hydraulic downtime for cotton gins.  On top of that, threaded connections are susceptible to vibration and a common source of leakage.

► SmartFlow™ is Compatible with Any Press and Any Control Panel

Don't want to replace your press or controls?  No problem!  Some companies will not build a new hydraulic power unit unless you also invest in a new press.  That is not the case with Lubbock Electric.  New SmartFlow™ pumps will work with your press and controls no matter what brand they are.

► Lubbock Electric Co. is a One-Stop Shop

In addition to an expert hydraulic team, Lubbock Electric also has industrial electricians and controls programmers on staff.  After we build your unit, we can make the electrical changes to the console and wire it in.  If you need a new controls, we can also design and build custom press console for your gin.

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Client Success Story

Meadow Farmers Coop GinMeadow Farmers Co-op Cotton Gin

In 2016, Lubbock Electric built a SmartFlow™ Hydraulic system for Meadow Farmers Co-op.  After the 2015 gin season, Dan Jackson knew that they needed to replace their aging hydraulic pumps. 

"Before installing Lubbock Electric's SmartFlow™ press pumps, we were still using Continental pumps from 1995.  Parts availablity became a huge problem for us."

Faced with growing lead times for obsolete parts, Dan began examining his options for a new power unit.  Meadow had a Continental press that was still in great working condition.  However, any other manufacturer required replacing the press with their brand. 

Fortunately, Lubbock Electric could provide him with what he really needed: new pumps, new controls, and no need to replace his press.  Plus, Lubbock Electric was a one-stop shop for the entire project, which was also important to Dan.

“I have to give kudos to Steve and his team. Everything was done promptly and on-site. We had a great experience with Lubbock Electric.”

During Meadow's first gin season with brand-new SmartFlow™ hydraulic power, Dan was surprised at the difference.

"SmartFlow™ is state-of-the-art.  We were using 20 year-old technology, so we saw a definite improvement in both speed and output.  During the last gin season, we ginned an average of 40-42 bales per hour.  This year, we ginned an average of 50 bales per hour most days.  That's 8-10 bales per hour better!"

If your gin is relying on decades-old technology to power your press, it might be time for you to consider retrofitting your gin.  Doing so will increase uptime during gin, boost your ginning speed, and decrease maintenance costs.

"Timeliness is everything in our business, especially for our customers.  That's why we're always looking for ways to increase efficiency.  If you're being efficient, you can take better care of your customers and enjoy a greater return.  It's win-win.  I think that we earned back our investment both in terms of return and taking care of our customers."

- Dan Jackson, Manager of Meadow Farmers Co-op Gin

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SmartFlow™ Cotton Gin Hydraulic Technology


More Speed, Fewer Problems

One thing that we admire about cotton gin managers is that they work hard to keep equipment in working order for as long as possible.  This is certainly the case when it comes to gin press pumps.  Since 1944, we have partnered with gins to restore hydraulic units to "like-new" condition.

At some point, however, your customers will be better served by truly new hydraulic units.

Here's why.  When you don't take advantage of gains in productivity you're leaving money on the table and falling behind your competition. 

Lubbock Electric's SmartFlow™ design for cotton gin hydraulic power units utilizes advanced hydraulic technology to boost ginning speed and eliminate common hydraulic problems. 

Cotton gins that have replaced their decades-old hydraulic equimpent with SmartFlow™ pumping units have experienced significant production gains.  Let's examine what SmartFlow™ can do for your business.

 

Key FeaturesClient Success StoryDetailed SpecificationsRequest a Quote

 


Key Features

► Unique "Baffling" Technology Filters Out Contaminants

Oil contamination is one of the chief causes of hydraulic failures.  Foreign contaminants in hydraulic fluid impede operational efficiency, cause corrosion, change the viscosity of the fluid, and accelerate wear and tear.

SmartFlow™ is designed to protect your equipment and maintain uptime.  In addition to hydraulic filters, SmartFlow™ uses a uniquely engineered baffling plate that filters contaminants inside the tank.

► Flooded Suction Prevents Cavitation

Another common cause of hydraulic breakdowns is cavitation.  Pump cavitation is the formation of vapor cavities ("bubbles") that occurs when the pressure in the pump inlet drops below the pressure of the liquid.  To save space, many traditional press pump units utilize a top-mounted configuration in which the motors and pumps are placed on top of the tank.  However, this design is prone to cavitation because the pump has to work against gravity to pull oil up.

SmartFlow™ involves a flooded suction design.  Pumps are placed below the minimum oil level, and gravity assists in creating pressure into the suction line.  This design makes cavitation nearly impossible.

Flooded Suction

► Three-Stage Vane Pumps Allow For More Oil & Speed

To be competitive, cotton gins need to gin more cotton in less time.  This is why SmartFlow™ uses three-stage vane pumps.  The increase in size from a two-stage to a three-stage pump allows for a greater volume of hydraulic fluid in the pump and higher pressure.

► Temperature Controllers & Oil Coolers Maintain Proper Oil Temperatures

Looking to gin more bales per hour?  Greater speed means that more heat will be generated.  Fluid temperatures above 180°F (82°C) can damage seals, impair system components, and accelerate degradation of the fluid.  We have incorporated advanced temperature controllers and powerful oil coolers into our SmartFlow™ design so that you can protect your hydraulic lines while increasing speed.

Temperature Controllers

► Flexible Hoses Simplify Replacing Pumps

SmartFlow™ uses hydraulic hoses instead of pipe to connect pumps to the hydraulic circuit.  This makes it much easier and quicker for repair technicians to replace and repair pumps and motors.  This also reduces the cost of service calls and decreases hydraulic downtime for cotton gins.  On top of that, threaded connections are susceptible to vibration and a common source of leakage.

► SmartFlow™ is Compatible with Any Press and Any Control Panel

Don't want to replace your press or controls?  No problem!  Some companies will not build a new hydraulic power unit unless you also install a new press from them.  That is not the case with Lubbock Electric.  New SmartFlow™ pumps will work with your press and controls no matter what brand they are.

► Lubbock Electric Co. is a One-Stop Shop

In addition to an expert hydraulic team, Lubbock Electric also has industrial electricians and controls programmers on staff.  After we build your unit, we can make the electrical changes to the console and wire it in.  We can also design and build custom press console for your gin.

▲Top

Client Success Story

Meadow Farmers Co-op Cotton Gin

Meadow Farmers Coop Gin

In 2016, Lubbock Electric built a SmartFlow™ Hydraulic system for Meadow Farmers Co-op.  After the 2015 gin season, Dan Jackson knew that they needed to replace their aging hydraulic pumps. 

"Before installing Lubbock Electric's SmartFlow™ press pumps, we were still using Continental pumps from 1995.  Parts availablity became a huge problem for us."

Faced with growing lead times for obsolete parts, Dan began examining his options for a new power unit.  Meadow had a Continental press that was still in great working condition.  However, any other manufacturer required replacing the press with their brand. 

Fortunately, Lubbock Electric could provide him with what he really needed: new pumps, new controls, and no need to replace his press.  Plus, Lubbock Electric was a one-stop shop for the entire project, which was also important to Dan.

“I have to give kudos to Steve and his team. Everything was done promptly and on-site. We had a great experience with Lubbock Electric.”

During Meadow's first gin season with brand-new SmartFlow™ hydraulic power, Dan was surprised at the difference.

"SmartFlow™ is state-of-the-art.  We were using 20 year-old technology, so we saw a definite improvement in both speed and output.  During the last gin season, we ginned an average of 40-42 bales per hour.  This year, we ginned an average of 50 bales per hour most days.  That's 8-10 bales per hour better!"

If your gin is relying on decades-old technology to power your press, it might be time for you to consider retrofitting your gin.  Doing so will increase uptime during gin, boost your ginning speed, and decrease maintenance costs.

"Timeliness is everything in our business, especially for our customers.  That's why we're always looking for ways to increase efficiency.  If you're being efficient, you can take better care of your customers and enjoy a greater return.  It's win-win."

"I think that we earned back our investment both in terms of return and taking care of our customers."

- Dan Jackson, Manager of Meadow Farmers Co-op Gin

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Detailed Specifications

  • Totally enclosed, fan cooled 125HP motors
  • Denison T6EDCS three-stage vane pumps rated at 233 GPM with a maximum pressure rating of 4100PSI
  • Two-pump units deliver 466 GPM
  • Three-pump units are rated at 699 GPM
  • Sixteen hundred gallon reservoirs are designed to settle out any contaminants, while dissipating heat.
  • Total weight: 15,500 lb. (Three pump unit)

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