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Introduction

A major steel manufacturer was using open roll work bearings in their plate rolling mill. The maintenance team was investigating grease alternatives. NSK was asked to provide a potential alternative for the bearing application with associated cost savings. By using an NSK Sealed Clean 4 row tapered roller bearing assembly the customer’s daily re-greasing rewuirement was removed. Additionally, this had the benefits of reduced grease disposal costs, continuous operation and bearing protection from external contamination.

Key Facts

  • Plate Rolling Mill
  • Open roll bearings required daily maintenance and regreasing
  • Efficiency improvement
  • NSK solution: Sealed Clean technology
  • Improved grease retention
  • Improved bearing protection
  • Large cost savings made by reducing grease consumption and maintenance time
  • Plate Rolling Mill
  • Extra-Capacity Sealed-Clean Four Row TRB Bearings

Value Proposals

  • Analysis of the existing bearings showed that grease retention and excessive maintenance were a major issue
  • NSK Engineers were able to select Sealed Clean bearing options together with improved material technology
  • Consideration of the existing bearing set up allowed NSK to make recommendations on best fit and appropriate bearing design
  • Technical support was then provided to trial the proposed bearing arrangement
  • Results showed a significant reduction in grease usage

Product Features

  • Super-TF or WTF steel material
  • Newly designed bearing internal geometry - wider cage diameter, increased number of rollers & larger rollers
  • Higher load capacity due to newly designed bearing internal geometry and special seal
  • Seals: New type of lateral seal, new bore seal
  • Main seal and seal holder with a more compact design
  • Special helical groove to prevent creeping on the roll neck shaft
  • New type of bore seal prevents the build-up of negative pressure that can cause the entry of water through the main seals
  • Super-TF steel provides significantly longer service life under heavily contaminated operating conditions
  • WTF steel provides significantly longer service life under water and metallic contamination
  • Sealed-clean solution significantly reduces grease consumption

Cost Saving Breakdown

Before Cost p.a. NSK Solution Cost p.a.
Cost of greasing current open bearings: 1.2 times per day × 4kg of grease × $4.30/kg cost of grease × No. of bearings × 350 days a year $28,929 Cost of NSK Sealed Clean design: bearings × 6kg of grease during re-grease × $13.94 cost of grease recommended by NSK $688
Cost of used grease disposal (per mill staff) $22,109 Cost of grease disposal (per re-grease) $71
Total Costs $51,038 $759

Reference:SS-E-0011

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