Success Story
Industry: Steel & Metals
Application: Quench Conveyor
Cost Savings: € 241 802
Introduction
A customer was facing mechanical failures on quench drives due to wear in the Teflon bushes supporting the quench rollers. This led to the rollers dropping and damaging the sprockets and chains, causing the manufactured steel shoe to stick. The result was poor heat treatment of the shoes and subsequent quality issues. NSK recommended replacing the Teflon bushes with stainless steel Molded-Oil bearings. The bearings were on trial for 12 months without problem and subsequently all bushes were converted in the quench area.
- Quench Conveyor
- Molded-Oil
Key Facts
- Quench conveyor
- Mechanical failure of rollers causing manufactured heat treated shoes to stick and therefore insufficiently quenched
- Poor quality heat treatment of shoes
- NSK Solution: Molded-Oil
- Improvement to quality of heat treatment
- Significant cost saving on downtime, parts and maintenance labour
Value Proposals
- NSK application review highlighted poor bearing life and costly downtime
- NSK recommended stainless steel Molded-Oil bearings which lasted 12 months operation without failure
- Additional benefit of not having to replace costly conveyor items - chain, sprokets and rollers
Product Features
- Available for high speed applications
- Available in Ball Bearing, Spherical Roller Bearing and Tapered Roller Bearing types
- Rust-proof - Stainless steel for corrosive environments
- Ideal for applications where contact with liquids and chemicals is unavoidable
- Seals made from nitrile rubber
- Contact-seal type available in standard inventory for ball bearings
- Able to minimise oil leakage
- Longer service life
- No need for re-lubrication
- Smooth rotation of rolling elements
Cost Saving Breakdown
| Before | Cost p.a. | NSK Solution | Cost p.a. | |
|---|---|---|---|---|
| Bearing Costs: Cost of parts replaced - Chain, Teflon bushes, Sprockets, Rollers | € 20.614 | Bearing Costs: Cost of Molded-Oil bearings | € 15.067 | |
| Costs of lost production: 55 hours downtime @ € 4.109 / hour | € 225.995 | Costs of lost production: No downtime | € 0 | |
| Engineering Costs: Labour for maintenance 380 hrs @ € 27 / hour | € 10.260 | Engineering Costs: No maintenance | € 0 | |
| Total Costs | € 256 869 | € 15 067 | ||
Reference:SS-E-2026
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