bearing repair

Rubber Plant Motor Failure

A 400HP WEG motor on the hydraulic power unit of a plant’s main mixer failed due to a catastrophic drive-end (DE) bearing issue. The bearing failure generated sparks and halted the production of raw rubber critical for automotive products. With the backup mixer already out of service—its old DC motor awaiting replacement in February 2025—production came to a complete standstill. Upon inspection, it was clear the inner race of the failed bearing had welded itself to the motor shaft. The motor was promptly sent to Horner Machining Services (HMS) division for shaft repair. Once disassembled at Washington Street, HMS discovered deep [...]

Rubber Plant Motor Failure2026-04-15T12:07:14-04:00

Coffee Creamer Bottle Motor/Gearbox Repair

In a coffee creamer plant, the blow molding machine was the backbone of the operation, producing 16oz and 32oz bottles. The process started with plastic pellets being fed into the machine through a hopper or screw. These pellets were heated and melted due to the combined effects of external heat bands and the friction generated by a rotating screw. The melted plastic was then shaped into a parison, a hollow tube with an opening at one end, which was clamped securely inside a mold designed to form the bottle. Compressed air was then forced into the parison, causing it to expand [...]

Coffee Creamer Bottle Motor/Gearbox Repair2025-07-23T13:36:11-04:00

7000 HP ID Fan Motors

In the dynamic landscape of energy production, Horner has been a steadfast partner in ensuring the operational excellence of a prominent coal-fired generating plant. This success story revolves around the maintenance and reconditioning of two critical 7000 HP induced draft fan motors, integral components of the plant’s power generation process. A real life example: (Not our customer) Kingston Fossil Plant near Knoxville, TN rely on the combustion of coal in a boiler to produce high-pressure steam. This steam, at temperatures exceeding 1,000 degrees Fahrenheit, propels turbines connected to genera- tors, generating electricity at an impressive 20,000 volts. The Kingston plant, with [...]

7000 HP ID Fan Motors2024-11-15T12:55:33-05:00

Underground Rock Quarry

I have previously expressed, that the unexpected challenges encountered in Field Service contribute significantly to the intrigue and appeal of the profession. My recent assignment required me to venture underground, an endeavor I found to be a genuinely remarkable experience, one that I would readily undertake again. I received a service call to balance the primary air supply fan at a local underground rock quarry. Upon arriving, I successfully completed the requisite safety training and prepared to descend below ground. To access the underground tunnel, I unloaded my van as diesel vehicles are the exclusive mode of transport permitted in subterranean [...]

Underground Rock Quarry2024-11-15T12:57:05-05:00

Starch Mixing Logs

          An ingredient manufacturer had damaged 20 foot mixing logs that mixed up starch. The customer gave us a tight schedule of 5 days to remove the damaged gears, coupling, bearings, and all bent and broken paddles. Basically receive it Monday and return them Friday! Horner Machining Services worked with Fan and Fabrication to get the job done. Machining straightened the shafts and fixed the gears and bearings. Fan and Fabrication laser cut and installed 64 new stainless steel paddles on the mixing logs. It took both divisions and three shifts through the week to make the [...]

Starch Mixing Logs2024-02-28T10:35:03-05:00

Process Equipment Repair Opportunity

Most customer accounts begin with small motor repair jobs and then graduate to larger motors and driven equipment repair work such as fans, gearboxes and pumps. A few of our customers have specialized process equipment that also needs service work to keep production rolling. One of our customers produces only one product – cellulous fiber, and they cannot make enough of it to satisfy the consumer demand for this product. Cellulose is found in all plant matter. This customer uses large rolls of white paper as their only source of cellulose. The wood pulp in the paper along with the starch [...]

Process Equipment Repair Opportunity2023-03-15T09:57:04-04:00

Aluminum Plant Outage

A major aluminum manufacturer contracts Horner EMDS (Electro Mechanical Diagnostic Services) to perform monthly vibration data collection and analysis. EMDS identified a mill gearbox input shaft bearing issue. In 2022, the monthly vibration analysis indicated the bearing issue increasing. The vibration analysis was discussed with the customer and the vibration data collection increased to twice weekly. At the same time, customer was planning a major outage to on-site repair the gearbox. The March outage was scheduled. Horner provided 24 hour per day, 5-day work schedule. On a Monday the outage started. Mark Rosebrock was lead tech on day shift and Matt [...]

Aluminum Plant Outage2023-03-14T11:27:59-04:00

Power Generation Plant Water Pump Motors

A coal fired power generation plant had a planned outage to maintain equipment and Horner was onsite to remove 2 1250HP vertical pump motors. These motors pull water from the reservoir for cooling purposes and heat exchangers. These motors were taken out for routine maintenance, basic reconditioning and to replace bearings. Onsite to help with the removal was Indianapolis Field Service Don Pence, Louisville Field Service Joe Dupont and Terre Haute’s Eddie Piper and Jeremy Brown. Crane service had to be scheduled and coordinated to pull the motors out. The bearings for these motors are specialized thrust bearings and were replaced [...]

Power Generation Plant Water Pump Motors2023-03-13T10:23:54-04:00

Steel Rolling Tandem Mill Motor

A steel manufacturer sent in a steel rolling tandem mill motor after the armature equalizer insulation had failed to ground due to age and time of service. The bearings, bearing journals, and bearing housings were severely damaged. A team of different Horner Divisions came together to complete this project. Machining Services did an extensive amount of machine work on the shaft and bearing housing. They also turned and undercut the armature when the rewind was completed. Fan and Fabrication manufactured new bearing seal inserts. Horner Coatings sprayed and machined the shaft and bearing housings. They also did the welding of the [...]

Steel Rolling Tandem Mill Motor2022-05-16T11:59:45-04:00

Compressor Room Electric Motor

A call came in late Friday from a customer planning to have their maintenance team do an onsite bearing change on a production compressor motor. We had the bearings in stock and set aside for them, however, Monday morning I received a call letting me know that they weren’t able to complete the work in house and requested Horner Field Service to come assist as soon as possible. We sent a team that morning to pull the motor and get it in to the shop for evaluation. Once onsite, they found that the compressor room is not accessible with a forklift. [...]

Compressor Room Electric Motor2022-05-16T11:51:07-04:00

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