Success Story
Industry: Quarrying, Mining & Construction
Application: Jaw Crusher - Main Bearings
Cost Savings: € 1 976 160
Introduction
In a Quarry in the UAE the bearings in a jaw crusher failed once per year. This led to replacement and massive production loss due to downtime. The competitor bearings failed due to wrong installation, a lack of proper lubrication and weak performance under high temperature. NSK and the distributor investigated the failures which resulted in a modification of the shaft & housing. The maintenance staff was trained how to install the new NSK bearings (heat stabilised up to 200 °C) with the proper lubrication. The result was outstanding, the bearing is running for 5 years without any signs of degradation resulting in savings of nearly 2 million Euros per year.
- Quarrying Mining Industries
- Spherical Roller Bearings - CAM Series
Key Facts
- A crusher in United Arab Emirates was experiencing premature failures in the main Jaw Crusher Bearings
- The bearings failed every 1 year leading to replacement, Downtime and massive production loss
- The competitor spherical bearings were failing due to several factors including lack of proper lubrication, installation procedures not followed properly
- NSK and the local distributor investigated that the process to install the large bearings were inadequate along with lubrication not provided in proper manner
- A lubrication study and optimization with shaft & housings modifications, training & supervision on NSK bearings installation were provided along with a heat stabilized bearings up to 200 °C degrees
- The result was outstanding as the bearing is running for 5 years without any signs of degradation resulting in savings of nearly 2 million Euros on an annual basis
Value Proposals
- A crusher in United Arab Emirates was experiencing premature failures in the main Jaw Crusher Bearings
- The bearings failed every 1 year leading to replacement, Downtime and massive production loss
- The competitor spherical bearings were failing due to several factors including lack of proper lubrication, installation procedures not followed properly
- NSK and the local distributor investigated that the process to install the large bearings were inadequate along with lubrication not provided in proper manner
- A lubrication study and optimization with shaft & housings modifications, training & supervision on NSK bearings installation were provided along with a heat stabilized bearings up to 200 °C degrees
- The result was outstanding as the bearing is running for 5 years without any signs of degradation resulting in savings of nearly 2 million Euros on an annual basis
Product Features
- A crusher in United Arab Emirates was experiencing premature failures in the main Jaw Crusher Bearings
- The bearings failed every 1 year leading to replacement, Downtime and massive production loss
- The competitor spherical bearings were failing due to several factors including lack of proper lubrication, installation procedures not followed properly
- NSK and the local distributor investigated that the process to install the large bearings were inadequate along with lubrication not provided in proper manner
- A lubrication study and optimization with shaft & housings modifications, training & supervision on NSK bearings installation were provided along with a heat stabilized bearings up to 200 °C degrees
- The result was outstanding as the bearing is running for 5 years without any signs of degradation resulting in savings of nearly 2 million Euros on an annual basis
Cost Saving Breakdown
| Before | Cost p.a. | NSK Solution | Cost p.a. | |
|---|---|---|---|---|
| Bearing Costs | € 3 360 | Bearing Costs | € 12 000 | |
| Engineering Costs | € 39 600 | Engineering Costs | € 13 200 | |
| Costs of lost production | € 2 448 000 | Costs of lost production | € 489 600 | |
| Total Costs | € 2 490 960 | € 514 800 | ||
Reference:SS-E-2-794
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