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

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 wellsite 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.

“Engineering for a 42-mile conveyor takes more than horsepower. It takes understanding application dynamics, thermal performance, and logistics at scale,” said Austin Burdette, HIG (Heavy Industrial Gearing) Product Manager at SEW-EURODRIVE USA. “Our X.e gear units and engineering teams delivered the reliability and performance required for a project of this magnitude.”

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.