Success Story
Industry: Pulp and Paper
Application: Paper Mill Combustive Air Unit
Cost Savings: € 7 203
Introduction
An important Italian paper company was having reliability problems with bearings fixed in a combustive air unit of a continuous paper machine. Bearings lasted 4 months on average and, in some cases, they broke down prematurely with correspondent costly unplanned maintenance operations. The customer requested an NSK technical proposal in order to increase bearings life. NSK engineers analysed the application and found high temperature was causing bearing failure. NSK proposed a high temperature specification bearing (heat treatment, seals and lubrication grease). The bearings are still running after 12 months, with reduced maintenance requirement. In addition, re-lubrication operations are no longer necessary.
- Paper Mill Combustive Air Unit
- High Temperature Sealed DGBB
Key Facts
- Combustive air unit
- Bearing failures due to high temperature
- NSK solution: Deep Groove Ball Bearing with high temperature features
- 3 times bearings life increase
- No unexpected machine downtime
Value Proposals
- NSK performed Application Review
- Failed Bearing Analysis showed bearing failures due to high operating temperature
- NSK proposed Deep Groove Ball Bearings with high temperature features resulting in 3 times longer bearing life
- No unplanned downtime
Product Features
- Steel Cage
- Heat treatedrings
- C3 Internal clearance
- High temperature grease
- Viton®* Seals
- "E" class (noise level)
- High performance in contaminated environment
- Temperature stability: up to 150°C
- Longer bearing life through superior seal performance
- Reduced noise level "E" class for electrical applications
Cost Saving Breakdown
| Before | Cost p.a. | NSK Solution | Cost p.a. | |
|---|---|---|---|---|
| Bearing Costs: Bearing replacements | € 292 | Bearing Costs: Bearing replacements | € 114 | |
| Engineering Costs: Maintenance time 3 hours/failure. Costs €25/h x 3 people | € 900 | Engineering Costs: Maintenance time 3 hours/failure. Costs x €25/h x 3 people | € 225 | |
| Costs of lost production: Downtime x 3 hours x €700/h. 4 replacements | € 8.400 | Costs of lost production: Downtime x 3 hours x €700/h. 1 replacement | € 2.100 | |
| Lubrication Costs: 24 operations x 5 min x €25/h | € 50 | Lubrication Costs: Lubricant is no longer necessary | € 0 | |
| Total Costs | € 9 642 | € 2 439 | ||
Reference:SS-E-4005
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