Success Story
Industry: Cement
Application: Concrete Pipe Cutting
Cost Savings: € 38 400
Introduction
A customer was experiencing repeated bearing failure every 2-3 months, on the blade support of a concrete pipe slotting machine, with 8 hours downtime per failure. NSK Engineers examined the application and determined that ingress of concrete dust was causing premature failure of the bearings. NSK recommended changing to Molded-Oil bearings, which would give a better service life. This resulted in much improved performance with bearing life quadrupled from 2-3 months to 12 months.
- Concrete pipe
- Molded-Oil
Key Facts
- Concrete pipe slotting
- Bearing replacement every 2-3 months with 8 hours breakdown per failure
- Concrete dust environment
- NSK solution: Molded-Oil bearings
- Significant reduction in downtime and maintenance costs
- Quadrupled bearing life from 2-3 months to 12 months
Value Proposals
- The customer was experiencing poor performance of the bearing on a blade support for a concrete pipe slotting machine.
- A failed bearing analysis concluded that ingress of cement dust contaminating the grease was the route cause of premature bearing failure.
- An application review showed that the existing shielded Deep Groove Ball Bearings were inadequate.
- NSK recommended Molded-Oil bearings with a DDU seal.
- A trial was conducted and the results showed no failures in a 12 months period.
- This resulted in a significant reduction in maintenance costs, improved productivity and zero lost production providing a large cost saving for the customer.
Product Features
- Molded-Oil provides continuous supply of lubrication oil
- Stainless steel for corrosive environments
- Grease-free property with no oil refilling keeps operating environments clean
- Operating life more than twice as long as grease lubrication, in water or dust contaminated environments
- Contact-seal type available in standard inventory for ball bearings
- Achieves extended maintenance-free performance as Molded-Oil provides a continuous supply of lubricant
- Available for high speed applications
- Available in ball bearing, spherical roller bearing and tapered roller bearings types
Cost Saving Breakdown
| Before | Cost p.a. | NSK Solution | Cost p.a. | |
|---|---|---|---|---|
| Engineering Costs: 4 failures per year | Engineering Costs: No failures over one year | |||
| Costs of lost production: 8 hours downtime per failure €1.200 per hour downtime costs |
€ 38.400 | Costs of lost production: NSK Molded-Oil bearings operated without failure for 12 months | € 0 | |
| Total Costs | € 38 400 | € 0 | ||
Reference:SS-E-2028
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