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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.

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

Concrete pipe Concrete pipe
Molded-Oil Molded-Oil

Background Information

  • Sector: Cement
  • Country: UK
  • End-product: Concrete pipe
  • Application: Slotting concrete pipe

  • Number of machines: 1
  • Approx. Lifetime: 2-3 months
  • Problem: Ingress of concrete dust behind seal resulting in premature bearing failure

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.
4 failures per year No failures over one year
8 hours downtime per failure
€1.200 per hour downtime costs
€ 38.400 NSK Molded-Oil bearings operated without failure for 12 months € 0
Total Costs € 38.400 € 0

Reference: SS-E-2028

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