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Introduction

An abattoir was experiencing frequent breakdowns due to bearing failures on a band saw application. Two bearings in back-to-back configuration were mounted on each band saw wheel, which supported the cutting blade and rotated at 1500rpm. Water ingress caused corrosion on the running surfaces and lubricant was degraded from the daily mashine wash. Due to this the bearings had to be replaced 8 time per year. NSK reviewed the application and investigated this problem. NSK recommended to replace the existing bearings by stainless steel Deep Groove Ball Bearings with DDU seals and Molded-Oil lubrication. This resulted in a significant lifetime extension and cost saving.

Key Facts

  • Frequent bearing failures occurring every 6 to 7 weeks
  • Water ingress from frequent wash down resulting in lubricant degradation and corrosion of the rolling elements and raceways
  • NSK Solution: Stainless steel Deep Groove Ball Bearings with DDU seals and Molded-Oil lubrication
  • Significant lifetime increase
  • Band Saw
  • Deep Groove Ball Bearing with Molded-Oil

Value Proposals

  • NSK Application Review determined the bearing failure due to degradation of the lubricant and ingress of water
  • NSK recommended the use of stainless steel Deep Groove Ball Bearings with DDU seals and Molded-Oil lubrication.
  • Molded-Oil bearings use an oil impregnated polymer as the lubricant instead of grease. The polymer matrix slowly releases oil to lubricate the bearing, while at the same acting as a barrier to protect the bearing from contamination. The lubricant cannot be washed out as with standard greases and therefore the life of bearings in wet environments can be increased significantly.
  • A trial resulted in a substantial increase in bearing life and a reduction of the machine down time

Product Features

  • Molded-Oil provides continuous supply of lubricant
  • Grease-free propertywith no oil refilling keeps operating environments clear
  • Operating life more than twice as long as grease lubrication, in water or dust contaminated environments
  • Contact-seal type available in stadard inventory for ball bearings
  • Achieves extended maintenance-free performance through constant supply of lubricant; availble for high speed applications
  • Available in ball bearings, spherical and tapered rolling bearings
  • Stainless steel for corrosive environments

Cost Saving Breakdown

Before Cost p.a. NSK Solution Cost p.a.
Old bearing design € 525 New bearing design € 248
0,5 hrs downtime x 8 times/year x €586/hr € 2.344 No downtime € 0
1 hr fitting time x 8 times/year x €25/hr + frequent blade failure cost € 942 Initial fitting time 1 hr x 25/hr + normal blade replacement cost € 135
Annual lubrication cost € 1.945 No re-lubrication € 0
Total Costs € 5.756 € 383

Reference:SS-E-2084

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