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Success Stories

Results proven in the field

See the difference NSK solutions make in real plants: each story covers the problem, the solution applied and the annual cost saving achieved.

Application Examples

Real plants, measured gains

Continuous Casting Machine

Total Cost Saving

€140.000

Continuous Casting Machine

An international steel producer suffered regular bearing failures on a continuous casting machine. Under heavy loads, wear and fatigue kept standard bearing life short: average life was 124 weeks and three failures had occurred. NSK recommended a durability trial with SWR Spherical Roller Bearings, made from specially developed bearing steel with far better wear and fatigue resistance.

Gas Turbine Blade Casting

Total Cost Saving

€100.095

Gas Turbine Blade Casting

A company was experiencing short service life on bearings used in gas turbine blade casting. An extremely aggressive solution combined with high loads and misalignment caused lubrication and retention problems. Alongside improvements in sealing and lubrication, an alternative wheel design using sealed cylindrical roller bearings was proposed; performance improved dramatically and service life doubled.

Wire Forming Production

Total Cost Saving

€1.202.455

Wire Forming Production

A customer suffered repeated failures on bearings fitted to rotating equipment in a wire drawing machine, causing extended downtime and high maintenance costs. NSK's investigation identified the problem in the lubrication and sealing arrangement. A specially selected Lithium Complex grease and sealed double-row cylindrical roller bearing unit were trialled; bearing performance increased, efficiency improved and maintenance costs fell.

Plate Rolling Mill

Total Cost Saving

€46.904

Plate Rolling Mill

A steel producer was using open roller work-roll bearings requiring daily relubrication on a plate rolling mill, and the maintenance team was looking for an alternative to the grease in use. With NSK's sealed-clean four-row tapered roller bearing arrangement the need for daily greasing was eliminated; grease disposal costs fell, continuous operation was achieved and the bearing was protected from external contamination.

Continuous Annealing Process

Total Cost Saving

€372.555

Continuous Annealing Process

A continuous annealing line at a steel plant was experiencing an average of 17 hours of downtime per year, costing approximately €21,915 per hour of failure. NSK engineers who analysed the failed bearings determined that both the bearing type and the sealing arrangement were inadequate for the application; the ideal solution was multi-row sealed cylindrical roller bearings (crane sheaves).

Quenching Conveyor

Total Cost Saving

€241.802

Quenching Conveyor

A customer experienced mechanical failures on quenching drives caused by wear in the Teflon bushes supporting the quenching rollers. This led to rollers dropping, damage to sprockets and chains, and the manufactured steel shoes sticking. NSK recommended replacing the Teflon bushes with stainless steel Molded-Oil bearings; after a 12-month trial all bushes in the quenching area were replaced.

Cold Saw for Steel Tubes

Total Cost Saving

€72.000

Cold Saw for Steel Tubes

A global steel company had problems with a cold saw used to cut steel tubes to length. The simple ball bearing supporting the axial movement failed every 6 weeks, causing unplanned maintenance. Analysis showed that the ball screw arrangement generated heavy axial impact loads and the original design was not robust enough to withstand them; NSK recommended the WBK ball screw support with far higher axial load capacity.

Dust Extraction Fan

Total Cost Saving

€88.955

Dust Extraction Fan

A customer faced high temperatures on a dust extraction fan application at an ore preparation plant; bearing temperature was being reduced with compressed air at high cost. An application review including thermal analysis revealed sealing problems: seal lip burning caused by high speed together with over-lubrication was driving the temperature rise. SNN Plummer Blocks and NSKHPS Spherical Roller Bearings with labyrinth seals were recommended with correct lubrication intervals and quantities; compressed air cooling was no longer needed.

Rotary Coal Valve

Total Cost Saving

€292.136

Rotary Coal Valve

A customer experienced serious recurring failures three times a year on a bearing fitted to a rotary coal valve at an ore preparation plant. NSK engineers determined the existing bearing design was inadequate for the high temperatures involved and recommended an RHP HLT bearing insert inside a Self-Lube cast iron FC housing, together with a ring made of heat-resistant material and an NSK adapter plate. The installed bearing units ran without failure for 12 months and the need for compressed air cooling was eliminated.

Air Recirculation Fan

Total Cost Saving

€393.706

Air Recirculation Fan

A customer suffered regular bearing failures on an air recirculation fan at an ore preparation plant, and a compressed air cooling system was used to reduce the high operating temperature of the bearing. An application review including a thermal study of the fan and bearings identified serious issues such as incorrect mounting, over-lubrication and inadequate sealing. NSKHPS Spherical Roller Bearings with labyrinth seals inside NSK SNN Plummer Blocks were recommended; no failure occurred for over 12 months and the compressed air cooling system was removed.

Rotary Coal Valve (HLT)

Total Cost Saving

€144.694

Rotary Coal Valve (HLT)

An international steel producer experienced failures twice a year on a bearing in a rotary coal valve at an ore preparation plant, causing significant production loss and damage to related components. The assessment determined that the existing bearing design was not adequate for the high temperatures. NSK recommended a special HLT bearing inside a Self-Lube cast iron FC housing together with a dedicated thermal insulation washer. The fitted bearings ran for more than 12 months without a single failure.

Wire Guides

Total Cost Saving

€10.000

Wire Guides

A wire manufacturer in France frequently encountered damage to finished products because of bearing failures in wire guides fitted with deep groove ball bearings. The bearings failed on average every 6 weeks due to dirt ingress behind the seals. NSK recommended replacing the existing bearings with Molded-Oil lubricated, DDU-sealed stainless steel deep groove ball bearings; bearing replacement dropped to 3 times a year.

Coil Preparation Gearbox

Total Cost Saving

€17.450

Coil Preparation Gearbox

A steel rolling mill was planning to use NSK for the first time in the bearings of a large gearbox that coils plate steel produced in the cold rolling process. During commissioning tests more noise than expected was detected and vibration analysis was inconclusive. The customer wanted to strip the bearings — which would have meant delays in production and high additional costs. Before any action was taken, an NSK AIP specialist carried out a detailed Condition Monitoring (CMS) service: the bearings were found to be running in optimum condition, no stripping was needed and commissioning tests were completed successfully.

Steel Production Machinery (Pilger Mill)

Total Cost Saving

€159.933

Steel Production Machinery (Pilger Mill)

A plant producing seamless stainless steel tubes suffered continuous bearing failures on a Pilger mill, with a service life of about 1 month. NSK's technical analysis identified the root problem as excessive load and inadequate lubrication combined with heavy operating conditions. A special spherical roller bearing with optimised internal design using Super Tough (STF) steel was recommended; the trial showed the new bearings lasted up to 200% longer.

Cold Rolling Mill — WTF Steel

Total Cost Saving

€26.400

Cold Rolling Mill — WTF Steel

A major steel producer was not satisfied with the performance of a four-row tapered roller bearing installed at a cold rolling facility. The problem was steel scale from the production process entering the bearings and undermining system reliability. NSK put the bearing and lubrication processes through detailed analysis; the use of NSK Tough (WTF) technology, far more resistant to damage caused by scale ingress, was recommended.

Cold Rolling Mill — STF Steel

Total Cost Saving

€16.300

Cold Rolling Mill — STF Steel

A steel manufacturer suffered continuous bearing failures at its cold rolling mill. NSK's application review determined that highly contaminated operating conditions were causing unexpected failures; bearing life was only 3–4 months. To combat residual contamination in the lubricant, NSK STF (Super Tough Steel) spherical roller bearings made from super-hardened steel were recommended. After a four-month trial, laboratory examination showed a remaining service life of 29–50 months; the customer now replaces the bearings once a year during planned maintenance.

Continuous Casting Machine (Spain)

Total Cost Saving

€14.850

Continuous Casting Machine (Spain)

A manufacturer of steel profiles had problems on a continuous casting machine: the cylindrical roller bearing mounted on the casting roll had an average service life of 1–2 months, and the machine had a highly complex cooling/lubrication pipe system; reconnecting the pipework generated high maintenance costs. NSK recommended mounting the segment bearings with sealed spherical roller bearings equipped with high-temperature grease; bearing performance increased significantly and considerable maintenance time was saved.

Hot Strip Mill

Total Cost Saving

€154.000

Hot Strip Mill

A major steel manufacturer wanted to extend the replacement intervals of the 4-row tapered roller bearings used on a hot strip mill; because of the demanding conditions, standard bearings ran for approximately 1,400 hours. NSK examined the bearing units and operating conditions; a new 4-row bearing with modified internal design and contact angle was put on test. The service life of the new bearing reached 2,200 hours.

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