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Introduction

A vegetable preparation manufacturer in the UK was experiencing frequent breakdowns with their Biogas plant due to bearing failures within a rotary screen. Two Deep Groove Ball Bearings were mounted within each wheel, with two wheels per rotary screen.
On average the bearings failed every 6 weeks, taking 1 hour each time to replace and incurring a significant loss of production per day. The bearings were failing due to ingress of contamination behind the seals. NSK engineers performed an Application Review and recommended that the existing bearings be replaced with Stainless Steel Molded-Oil Deep Groove Ball Bearings with DDU seals.

Key Facts

  • Biogas Plant - rotary screen
  • Bearing replacement every 6 weeks (8 times per year)
  • Contaminated environment
  • NSK solution: Stainless Steel Molded-Oil Deep Groove Ball Bearings with DDU seals
  • Bearing replacement reduced to 3 times per year
  • Significant cost saving on downtime and maintenance.
  • Biogas plant
  • Deep Groove Ball Bearing with Molded-oil

Value Proposals

  • The customer experienced many failures in a Biogas Plant rotary screen application.
  • NSK engineers performed a Failed Bearing Analysis which showed ingress of contaminants from the production process as the cause
  • An Application Review showed that the existing 2RS sealed Deep Groove Ball Bearings were inadequate
  • NSK recommended Stainless Steel Molded-Oil Deep Groove Ball Bearings with DDU seals
  • Since introduction the bearing life and machine performance has been significantly improved, which has resulted in reduced maintenance and downtime, 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.
Bearing Cost:
Total 32 replaced per year
€ 134 Bearing Cost:
Total 12 replaced per year
€ 992
8 breakdowns per year
51€ maintenance costs per breakdown
€ 408 3 breakdowns per year
51€ maintenance costs per breakdown
€ 153
1,5 hours lost production per breakdown
2.641 € costs per hour
€ 31.692 1,5 hours per breakdown
2.641 € costs per hour
€ 11.884
Total Costs € 32 234 € 13 029

Reference:SS-E-2058