Success Story
Industry: Food and Beverage
Application: Dip Tank Conveyor Nose Roller
Cost Savings: $85,844
Introduction
A large producer of chewing gum was experiencing repeated bearing failures on their Dip Tank Conveyor Nose Roller. Bearings were needing changed approximately every 7 weeks which involved high maintenance costs and regular unplanned machine down time. NSK analyzed the applicaiton and discovered the bearing arrangement of three Deep Groove Ball Bearing Units assembled together flush, one set each side of the roller was an adequate arrangement for this type af applicaiton. This arrangement did not share the load and was affected by axial preload. NSK proposed placing a spacer between each bearing to separate them and aviod axial loading. A test was initiated which resulted in an immediate improvement and significant lifetime extension.
Key Facts
- Bearing failures occuring approximately every 7 weeks
- 8 hours of manpower to replace failed bearings annually
- Substantial machine down time, 1 hour per roller and bearing set change
- NSK solution: use of spacers to separate bearings
- Significant lifetime improvement resulted with no failures over a 1 year period
- Productivity improvement
- Large annual cost saving achieved
- Dip Tank Conveyor Nose Roller
- Deep Groove Ball Bearing
Value Proposals
- Following repeated and costly failures the customer required a solution
- NSK performed an Application Review and discovered the three bearings fitted to each side of the roller were not designed for flush mounting. Spacers were placed between each to separate them and avoid axial preload
- A test was proposed using spacers and new sets of bearings
- This resulted in a reduction of machine downtime and maintenance costs with a significant annual cost saving with roller service life extended to 1 year
Product Features
- Cage made of steel, solid brass or plastic
- Electrically insulated roller bearings available
- Outer diameters up to 2500 mm
- Ultra pure steel - Bearing's life increasement by up to 80%
- Smaller axial loads in both directions
- Very high speed
- High grade balls for quiet and more consistent operation at higher speeds
- Bearing Spacer Shims
- Spacers allow two or more bearings to be flush mounted
- Prevent axial preload and ensure bearings share loads applied
Cost Saving Breakdown
| Before | Cost p.a. | NSK Solution | Cost p.a. | |
|---|---|---|---|---|
| Lost Production: 8 hours | $92,132 | Lost Production: 1 hour | $11,516 | |
| - Bearings - Spacer - Shaft & Roller |
$3,079 | - Bearings - Spacers - Shaft & Roller |
$374 | |
| Labor Costs: 8 hours | $2,883 | Labor Costs: 1 hour | $360 | |
| Total Costs | $98,094 | $12,250 | ||
Reference:SS-E-2065
