NSK Case Study

Application

Plate Rolling Mill

Cost Savings: $50,279

A major steel manufacturer was using open work roll bearings in their plate rolling mill. The mill maintenance team was investigating grease alternatives to gain efficiencies. 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 requirement was eliminated. In addition, reduced grease disposal costs, bearing protection from external contamination and continuous operation were achieved.

Key Facts

Plate Rolling Mill
Open work roll bearings required daily maintenance and regreasing
Efficiency improvement sought by the customer
NSK solution: Sealed Clean technology
Benefits: improved grease retention, improved bearing protection, reduced disposal costs and maintenance time

Plate Rolling Mill

Value Proposals

Analysis of the existing bearings showed that grease retention and excessive maintenance were a major issue
NSK Engineers were able to recommend Sealed Clean bearing options together with improved material technology
Consideration of the existing bearing arrangement 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

Available with Super-TF or WTF steel material, providing significantly longer service life under heavily contaminated operating conditions (STF) and water and metallic contamination (WTF)
Higher load capacity achieved with optimized internal design – wider cage diameter, increased number of rollers and larger rollers
Helical bore groove prevents creeping on the shaft
Advanced compact main seal / seal holder and bore seal designs
Bore seal prevents the buildup of negative pressure that can cause the entry of water through the main seals
Sealed-clean solution significantly reduces grease consumption
Extra-Capacity
Sealed-Clean
Four-Row Bearings

Cost-Savings Breakdown

  Before Cost NSK Solution Cost  
  Greasing open bearings: 1.2 times per day x 4 kg of grease x $4.30/kg x number of bearings x 350 days a year $28,929 NSK Sealed Clean design: bearings x 6 kg of grease x $13.94 $688  
  Grease disposal $22,109 Grease disposal (per re-grease) $71  
  Total Costs $51,038 Total Costs $759  
Before Cost
Greasing open bearings: 1.2 times per day x 4 kg of grease x $4.30/kg x number of bearings x 350 days a year $28,929
Grease disposal $22,109
Total Costs $51,038
NSK Solution Cost
NSK Sealed Clean design: bearings x 6 kg of grease x $13.94
 		 $688
Grease disposal (per re-grease) $71
Total Costs $759

Download Case Study PDF

Your Partner for Machine Optimization

Our AIP Added Value Program is based around a simple proposition: ‘improvement pays’. By working with you throughout the AIP Value Cycle, we will help you achieve improvements in machine reliability, productivity and performance, all of which carry a tangible and measurable cost benefit – and we have the tools to prove it! That’s what we mean by improvement pays.