Suffering from regular bearing failures on a feed conveyor at an animal feed production plant, the company´s maintenance team contacted NSK to see if the issue could be resolved. The investigations conducted by the expert team of specialists at NSK not only revealed the underlying cause of the problematic failures, but generated cost savings of over €13,000 for the plant, thanks largely to the elimination of machine downtime. An animal feed production plant is saving over €13,000 after adopting NSK Self-Lube Triple-Lip Sealed Bearing Units.
NSK´s investigations attributed the conveyor bearing failures to the ingress of hard particulates and moisture from process materials. As a result, it was recommended that the UK-based animal feed plant replace the standard self-lubricating units with Self-Lube Triple-Lip Sealed Units from NSK.
Since installation, the bearing units have been operating successfully for one year, which is in marked contrast to the previous situation whereby standard bearings required replacement every four months on average. These failures led to substantial downtime and costly loss of production. Now that these costs have been eliminated, and considering that fewer bearings are required over the course of a year, the annual cost savings for the plant have been calculated at €13,309. In addition, there has been a notable improvement in productivity thanks to greater conveyor uptime.
NSK´s Self-Lube Sealed Units feature a nitrile rubber triple lip that is bonded to a protective pressed-steel shield. As a result, longer bearing life is achieved through superior seal performance. In addition, the bearing units provide extended re-lubrication intervals, which in turn greatly reduces maintenance costs and increases the productivity of machinery and equipment.
Self-Lube Triple-Lip Sealed Units offer simple implementation and represent a ready replacement for existing bearing units. They are available for both set-screw and eccentric locking collar insert options. A large size range is offered, in both metric and imperial specifications.
NTN-SNR makes food-processing the flavour of the month
NTN-SNR, a leader in precision mechanics, is pressing ahead with food safety. The company plans to invest in its solutions for the food-processing industry as a way to optimise and strengthen its short-term range. The goal is to achieve optimal production with no risk to the user. This is necessary investment for a sector with increasingly stringent standards…
The average cost worldwide for product recalls in the food-processing industry was €7.92 million between 2012-2017. In 75% of cases, the causes were contamination with bacteria or allergens, or the presence of a foreign body. Despite strict standards, the food-processing market is the French industry leader, with a turnover of € 180 billion in 2017. It also ranks second among industrial sectors most affected by product recalls and withdrawals (16%), after the automotive industry. This presents a risk both to consumers’ health and to companies’ reputations, which are suffering considerable losses.
With this in mind, NTN-SNR, with its 30-year market presence, is pooling its strengths and developing its dedicated teams with a view to making the food-processing business its new battleground. The company’s repositioning brings fresh challenges, including rethinking and reintegrating all of the sector’s constraints, and reidentifying the various segments and ranges to meet each need as accurately as possible, while remaining accessible to all market participants.
A highly constrained environment
With its high-pressure washing, cleaning agents, humidity, fine particles, hygiene standards, high production rates, etc., the food-processing industry is a highly constrained environment.
NTN-SNR relies on its expertise to ensure that health standards-compliant, sustainable production is tailored to each sector of activity.
As of this year, the company is focusing on developing its existing ranges, with Germany and Italy as the main European targets for machine manufacture and France and Spain for maintenance.
NTN-SNR’s short-term food-processing market goals are to eliminate incident risks, reduce maintenance times to increase profitability, and to ensure peace of mind.
Fully suited solutions
To this end, the company offers a wide range of bearings, lubrication solutions, linear guides and stainless steel or thermoplastic self-aligning bearings. NTN-SNR has chosen to offer all-stainless steel bearings, where some market players only offer it for the insert, in combination with an anti-corrosion coated housing. The inserts are equipped with an elastomer seal protected by a shield to counter any impact or mechanical stress. As for the additional protective caps, they are provided with a radial or double-lip seal, offering additional resistance to high-pressure washes, even when in direct contact. These systems are true shields against moisture and dirt.
For added convenience, NTN-SNR inserts are available with Lubsolid® solid food grease. Fifty-five percent of premature bearing failures result from improper lubrication – a fact that led the company to design its flawless lubricant. The polymer matrix containing a large amount of oil completely fills the free space inside the bearing. As a result, neither pollutants nor water can enter.
The grease’s solid state means that it cannot flow, ensuring the cleanliness of your environment.
These properties increase the duration life of the bearing by up to 20 times compared to a part lubricated using a standard high-performance grease.
The appeal of this technology and growing user demand are behind the company’s plans to invest in its solid food grease. The goal is to secure production while increasing its manufacturing capabilities.
3 questions to Kévin Gay, NTN-SNR Market Manager
Why has NTN-SNR decided that this is the time to strengthen its presence in the food-processing industry?
It’s a gigantic market. The food-processing industry is the largest European manufacturing market. Market constraints mean that innovation is a constant, necessary feature.
NTN-SNR is one of the world’s leading bearings manufacturers. It is known in particular for its presence in the automotive, industry and aerospace markets. The company is also a player – albeit a more cautious one – in the food-processing market. Now, however, it seems vital that we emphasise our solutions and further develop our ranges to put forward options that are increasingly adapted to the many demands encountered by today’s manufacturers.
What is NTN-SNR’s added value compared to the competition?
Every experienced market player has high levels of technical skill and specific expertise (bearings, ball bearings, etc.). That being said, while designing reliable, innovative and qualitative products is essential to protect against bacterial growth, you can’t ignore the cost. Certain premium-quality ranges on the market have a rather high price tag. However, of the 300,000 companies making up the European market, 99% are SMEs with sometimes limited maintenance resources. As a result, they are forced to turn to lower cost solutions. For NTN-SNR, guaranteeing the accessibility of quality products in terms of cost to all food-processing stakeholders offers peace of mind.
What do you mean by “peace of mind”?
“Peace of mind” is one of the cornerstones and drivers for how we respond to the constraints of the food-processing business. It has several aspects.
First, there is health-related peace of mind – of the consumer, of course, but also of the manufacturer. On the business side, economic peace of mind is also a key point. With quality equipment, the maintenance manager can increase his operating intervals, thus increasing production. Peace of mind thus equates to saving time, productivity and profitability.
A wide range
- Topline ball bearings
- Thermoplastic mounted units
- Stainless steel mounted units
- Stainless steel ball bearings
- Linear axis and ball bushings
- Lubsolid®, solid food grease
- Lubrication solutions
NSK launches J-Line – a new range of JIS standard bearing units
NSK is expanding its existing RHP branded Self-Lube® range of bearing units to include products made to the JIS standard. With this new J-Line series, NSK also introduces a new packaging design.
The J-Line bearing units comprise six of the most popular housing types: pillow block with/without feet, square and round flange, two-hole flange, and take-up unit. Also available are three pressed-steel housings and five inserts (wide and narrow set screw, wide and narrow lock collar, and adaptor sleeve) covering bore diameters that range from 12 to 90mm. The units are built on demand, offering the highest flexibility for customers.
J-Line bearing units will be easily identifiable in their new, fresh NSK packaging design for the European market.
Ready to ship from April 2019, J-Line bearing units are suitable for use in sectors that include agriculture, cement, construction, food, material handling, packaging, paper, steel, textiles and many others.
To help simplify selection, NSK has published a new Bearing Unit Catalogue containing both J-Line and Self-Lube ranges. An electronic version will be placed on the NSK website ready for download.
NSK Europe Ltd. is the European organisation of the Tokyo-based bearing manufacturer NSK, which was founded in Japan in 1916 and today employs around 31,000 people in its worldwide operations. The products and solutions provided by the industrial and automotive supplier can be found wherever things move. In addition to nearly all types of rolling bearings, the company´s portfolio includes housed bearings, linear technology, wheel bearing units, transmission and engine bearings and steering systems. The company is oriented to perfection in all of its business activities. Its aim is quality leadership in its industry, which it strives for through a continuous process of improvement, excellent product development, optimised production processes and customer-oriented service processes.
NTN-SNR’s SMART TEMP: Parts heated and mounted in complete safety for optimal reliability
NTN-SNR launches SmartTEMP, its new range of induction heaters. They control the temperature whilst mounting, to preserve the integrity of the materials and ensure total safety when mounting components (bearings or gears). Heating gradually and controlling temperature deltas, preserves the functionality of sensitive parts. The touch screen along with the ability to store heating information leads to better traceability. Ease of use and the scope of range make SmartTEMP a very high-performance tool for all industries. With this innovative induction heating device, NTN-SNR furthers the dissemination of good practices concerning the heating and mounting of rotating parts. This is an essential phase when one considers for instance that 17% of bearing failures are caused by incorrect mounting. With the market release of SmartTEMP, NTN-SNR continues to pursue its objective of improving the productivity of its industrial clients by extending the useful life of their parts and machines. Unique cutting-edge functionality The SmartTEMP range offered by NTN-SNR is designed primarily to ensure the safety of the operator and the part being heated. The unique design featuring a coil system beneath the workpiece heats the bearing’s two rings evenly and consistently to prevent any temperature distortions between the different components. Two probes constantly control the difference in temperature between the two rings, thereby ensuring full control of the heating process and the total integrity of the bearing’s physical characteristics. The range comprises seven models that are capable of heating parts with masses ranging from a few grams to 1.6 tons. The RAMP mode allows the rise in temperature to be set evenly over a given period of time in order to heat up sensitive parts very gradually. This innovation is crucial for protecting such parts as gears, whose teeth may become brittle if heated too quickly. The SmartTEMP ensures accurate control over the mounting procedure to fully protect the integrity of the physical characteristics of the materials making up the various parts being heated. It thereby extends the useful life of rotating parts and the machinery.
High performance, user-friendly and a rugged design
The SmartTEMP’s new processor optimises the device’s performance by adapting its power requirement to the characteristics of the part. The current efficiency rises to 0.8 against 0.3 with a traditional heating device. Heating time is thus reduced by 30%, thereby offering significant energy savings. The SmartTEMP features an easy-to-use and intuitive touch screen. The software, which can be set to the operator’s language, downloads the heating data and exports it on a USB stick for full traceability of the mounting of the part. Nowadays this data is essential for connected 4.0 factories, the unit can also carry out self-diagnostics. In order to operate continuously, SmarTEMP’s new design is rugged and highly reliable. The electronic components are located in a separate compartment, and the aluminium frame enable it to bear heavy weights, withstand impacts and extreme temperatures.
Over 17% of bearing failures recorded by NTN-SNR are due to mounting errors, particularly uncontrolled heating of the parts, which is sometimes carried out using a blowtorch or oil bath, which have no accurate temperature control. The recommended heating temperature is generally 110°C, but this can vary according to the materials. Through its Experts & Tools service, NTN-SNR is keen to pass on information regarding good practices, training and the use of the correct tools. The SmartTEMP, is available for all industrial maintenance professionals, ensuring precise mounting of component parts and so increasing the productivity of the machines.
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