SEW-EURODRIVE Powers One of the World’s Longest Single-Flight Conveyor Systems

42-mile Dune Express conveyor showcases advanced industrial engineering, heavy-duty reliability, and large-scale logistics innovation.

Lyman, SC – SEW-EURODRIVE is helping power one of the most ambitious bulk material handling projects in North America through its contribution to the Dune Express conveyor system, a record-setting 42-mile single-flight conveyor designed to transport frac sand across the Permian Basin.

Developed by Atlas Energy Solutions in collaboration with system integrator Voith Turbo, the Dune Express system is designed to move up to 13 million tons of frac sand annually from Kermit, Texas, to the New Mexico border. The infrastructure-scale conveyor is expected to significantly reduce truck traffic, roadway congestion, fuel consumption, and associated emissions while improving logistics efficiency for well-site operations.

To support the extreme demands of the application, SEW-EURODRIVE supplied 36 custom X.e Series helical-bevel heavy industrial gear units engineered specifically for continuous-duty performance in rugged desert conditions.

The project required advanced thermal validation, high torque capacity, precision mechanical integration, and long-term reliability across one of the most demanding conveyor applications ever constructed.

SEW-EURODRIVE engineers collaborated closely with Voith Turbo throughout the project to deliver:

• Gearbox sizing matched to application dynamics

• Thermal performance modeling and bearing life analysis

• Mechanical interface verification and fabrication support

• Integrated condition monitoring and safety specifications

• On-site commissioning and logistics support

The conveyor system incorporates multiple SEW-EURODRIVE X.e Series gear units ranging up to 900 horsepower and more than 1.46 million lbs-in. of nominal output torque, highlighting the scale and technical sophistication of the installation.

Beyond the engineering achievement, the Dune Express represents a major evolution in bulk material transport infrastructure for the oil and gas industry. By replacing significant volumes of truck-based sand transportation with a continuous conveyor system, the project is expected to improve operational efficiency while reducing environmental and roadway impacts throughout the region.

About SEW-EURODRIVE

Founded in 1931 in Bruchsal, Germany, SEW-EURODRIVE is a global leader in Industrial Automation, with operations in over 50 countries, 17 manufacturing plants, 92 assembly facilities, and more than 21,000 employees. The company holds over 1,000 patents, continuously driving technological advancements in gearmotors, frequency inverters, servo drives, and Industry 4.0 solutions.

SEW-EURODRIVE provides engineered solutions in countless industries, including automotive, food & beverage, pharmaceuticals, mining, steel, logistics, energy, and more, providing customized automation solutions that enhance efficiency, productivity, and sustainability. Despite its global reach, SEW remains family-owned, ensuring long-term vision, strong values, and a commitment to excellence.

SEW-EURODRIVE. Driving the World™

SEW-EURODRIVE, Inc.
220 Finch Road
Wellford, SC 29385
(P): (864) 439-7537
cslyman@seweurodrive.com
www.seweurodrive.com 

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