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Success Story

Industry: Quarrying, Mining and 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.
Crusher in Quarrying Mining Industries
  • Quarrying Mining Industries
Spherical Roller Bearings - CAM Series
  • 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

  • NSK analysed the application suggested heat stabilised bearings to save downtime and improve output
  • NSK Spherical roller bearing with very high load capacity and long life replaced the existing product
  • The bearings were fitted and performed for 5 years without any intervention
  • Contaminant ingress reduced and lubrication reduced, giving greater savings to the customer

Product Features

  • Optimum raceway design & surface finishing
  • Up to twice the operating life
  • Highest load rating SRB's
  • Temperature stability: up to 200° C
  • Up to 20% higher limiting speed
  • Lower maintenance cost and improved productivity

Product Sheet >>

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