Success Story
Industry: Steel & Metals
Application: Pilger Mill
Cost Savings: € 159 933
Introduction
A Steel Mill customer was experiencing regular failures on bearings in their Pilger Mill. NSK investigated this and found that the main problems were severe operating conditions with high loads and inadequate lubrication. NSK proposed a special Spherical Roller Bearing with optimised internal design and Super Tough (STF) steel. A trial showed that the new bearings gave a 2 times longer life and a consequential reduction in maintenance costs.
- Seamless Stainless Steel Pipe and Tubes
- Bearings TF Series
Key Facts
- Pilger Mill application
- Bearings failure due to heavy and severe operating conditions
- NSK solution: Special Spherical Roller Bearings made in STF steel
- Bearings reached 2 times longer life than old bearings
- Reduced maintenance and plant stoppage
- Cost saving generated
Value Proposals
- NSK application technical analysis
- NSK proposed bearings with Super TF steel
- Bearings reached 200% longer life than old bearings
- Reduced maintenance time
- No unexpected bearing failure and no unplanned downtime
Product Features
- Innovative heat treatment technology
- Outperforming standard bearing steel
- Up to 10 times service life with contaminated lubrication
- Up to twice the service life under clean lubrication
- Up to 4 times the service life at 160°C
- Less than one-third the rate of wear
- 40% improvement in seizure resistance
Cost Saving Breakdown
| Before | Cost p.a. | NSK Solution | Cost p.a. | |
|---|---|---|---|---|
| Bearing Costs: Bearing replacement costs | € 21.788 | Bearing Costs: Bearing replacement costs | € 8.799 | |
| Costs of lost production: Lost production: 2 hours x 2250€/hr x 52/year |
€ 234.000 | Costs of lost production: Lost production: 2 hours x 2250€/hr x 21/year |
€ 94.500 | |
| Engineering Costs: Labour costs: 31€/hr x 2 hrs x 2 People x 52/year |
€ 6.448 | Engineering Costs: Labour costs: 31€/hr x 2 hrs x 2 People x 21/year |
€ 2.604 | |
| Engineering Costs: Other material replacement | € 4.000 | Engineering Costs: Other material replacement | € 400 | |
| Total Costs | € 266 236 | € 106 303 | ||
Reference:SS-E-4002
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