Delivering Cost Savings - Brammer Bearings Brochure - Jul 2016... · bearing suppliers; SKF, NSK,...

BearingsDelivering Cost Savings

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Bearings: Delivering Cost Savings

Brammer is the UK and Europe’s leading bearing distributor, and the only Authorised Distributor for leading bearing suppliers; SKF, NSK, Timken, Schaeffl er and Cooper

Bearing Experts

By buying from Brammer, an

authorised distributor for the

leading bearing brands, you

can be assured of not only the

warranty and traceability of all

Why Choose An Authorised Distributor?

Every year we sell over 25 million bearings across

Europe. As a result, Brammer offers the largest, most

comprehensive range and stock of bearings anywhere

in Europe.

As the industry’s leading authorised distributor,

we pride ourselves on our product knowledge and

technical support which is available to all customers,

at all times. We also have a highly trained team of

experienced professionals to provide on-site repair

and installation services and offer technical help

and engineering solutions to minimise disturbances

and downtime.

Moreover, as an authorised distributor, we can also

provide technical support and advice direct from the

manufacturer if necessary; this includes any unique

or specifi c bearing advice or guidance that may be

required, as well as in-depth technical expertise.

To ensure that Brammer provides the highest level of

technical support at all times, with in-depth product

knowledge, awareness and complete understanding

of customers’ needs, staff regularly attend

manufacturers’ training courses.

To give you complete peace of mind, Brammer

also offers lifetime monitoring of bearings and our

extensive product knowledge enables us to plan

a service schedule for preventative maintenance

and ensure optimum performance throughout the

product life.

the products supplied, but the

latest design and specifi cation,

minimising risk of reworked, second

hand, poor quality components

from unauthorised sources.


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Highest quality bearings for longer life and optimal performance

• The widest range and largest stock of

bearings anywhere in Europe

• Leading technology innovation from our

strategic supply partners

Access to technical expertise

• Exceptional product knowledge available

to all customers at all times

• Trained team of experienced professionals

provide on-site repair

• Technical support offered 24/7

• Technical support and advice direct from the

manufacturer if necessary

• If required, unique or customised bearing

guidance provided

Preventative maintenance

• Lifetime monitoring of bearings

• Planned service schedule to ensure optimum

performance throughout product life

• Forward planning to predict bearing failure

• Pre-planned product replacement at appropriate

calculated dates

• Unscheduled downtime avoided

• Preventative maintenance delivers cost savings

Access to manufacturers’ training

• Brammer staff regularly attend manufacturers’

training courses

• Staff trained to deliver most up-to-date

technical support at all times

• Training can be arranged for customer’s

specifi c needs on request

Brammer understands the importance

of maintaining production line

integrity and the fi nancial impact of

downtime resulting from breakdowns.

Also, Brammer’s guaranteed quality

assurance, consistent part

numbering, total product traceability

and a full manufacturer’s warranty

far outweighs any short term

purchase savings.

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Why Choose Brammer? Brammer is the UK’s number 1 supplier for bearings from leading manufacturers.

Same day delivery on stocked bearings from

your local branch

We always recommend the right bearings

Competitive pricing

Expert technical support available

nationwide

Our specialists save you time,

effort and money

Over 2 million bearings available

in stock

£

£

1

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Brammer shares valued partnerships with many suppliers which help deliver cost savings worth millions of pounds for customers every year.

We specialise in continuously striving to identify

processes that we can add value to with our

expertise so that customers can achieve and

overcome their cost saving targets.

Brammer’s Capabilities That Help Deliver Cost Savings

Services

• Local, national and pan-European service and

inventory profi le to meet customer needs

• Wide range of bearings available, enabling

customers to consolidate their supply, leverage

their spend and minimise their transactional costs

• Bearing refurbishment programme, reducing

costs and lead times

• Local service and technical support

24/7/365, right across Europe

• Technical consultancy, stock profi ling,

waste walks and Insites™ all deliver real

cost savings directly to our customers

• Complete pan-European visibility and almost

immediate availability of stock across Europe to

minimise customer inventory, reduce working

capital and avoid downtime

Cost Savings Training

• Market leading experience in bearings

• Sophisticated and segmented understanding of key

industry processes and bearing needs and

challenges our customers face

• Onsite and relevant bearing training

• Quality assurance that bearings supplied are new,

genuine, and the latest technology

• Guarantee that bearings provided are always

manufactured in accordance to a strict quality

management system

Cost Savings

• Proven ability to deliver value added solutions

and capture cost savings

• Wide range of solutions and products which

help extend bearing life and reduce downtime

• Innovative maintenance tools and condition

monitoring solutions to increase productivity

• Original Equipment Manufacturer interchange to

reduce costs and rationalise suppliers

• Streamline and standardise customers’

purchasing and invoicing for effi ciency and

reduction in total acquisition costs

• Asset tagging and product management to

identify risk as well as effi ciency gains

• Unparalleled insights into manufacturing

business needs coupled with sophisticated

management information to drive cost

benefi ts through customers’ supply chain

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Case Study 1

Case Study 2

Amount Saved

Amount Saved

Product

Product

Industry

Industry

£109,880

£7,500

Self-aligning Bearing System

Fryer Bearing Unit

Films, Adhesives and Printing

Food and Beverage

A leading polyester film manufacturer was experiencing high costs,

and shaft problems due to using special housings and bearings in its

industrial fans. After an examination, a self-aligning bearings system

was installed to optimise the application. The recommended system

included a CARB toroidal roller bearing in the non-locating position and

a self-aligning spherical roller bearing in the locating position to enhance

operating conditions and machine performance. As a result, the innovative

new system accommodated misalignment and axial displacement

without friction, and eliminated corrosion helping improve reliability and

productivity. The system was introduced to replace 80 units over a six year

period and allowed the customer to achieve cost savings worth £109,880

through increased bearing service life, extended maintenance intervals,

and reduced component and grease consumption.

One of the UK’s leading crisp and snack food manufacturers was facing

frequent bearing failure in its fryers due to the hot, oil vapour filled

environment which caused them significant losses due to downtime

and repair work. A team surveying the issue presented SKF’s fryer

bearing unit, specifically developed to provide optimum performance

in challenging environments with extreme temperatures, as the perfect

solution. The innovative system enabled cooking oil to lubricate the

bearings while preventing contaminants from entering the process;

productivity improved significantly and trouble-free operation without

frequent service intervals was achieved. The results were a dramatic

increase in bearing service life, in excess of 16,000 hours, and reduction

in other associated costs resulting in costs savings worth £7,500.


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Case Study 3

Case Study 4

Amount Saved

Amount Saved

Product

Product

Industry

Industry

£3,000

£6,000

Sealed Spherical Roller Bearing

High Temperature Bearing

Films, Adhesives and Printing Cement

Steel

A leading supplier of cement and ready-mixed concrete was

experiencing downtime and costs with their old system that used

housings, bearings and seals in a tail pulley. The building materials

supplier was recommended SKF’s Three-barrier solution that has been

developed specifically for highly contaminated and harsh environments.

The system includes sealed SKF Explorer spherical roller bearings, SNL

plummer block housings and labyrinth seals which result in machine

reliability and availability and drastically reduce downtime. The Three-

barrier solution proved to be ideal for use in the demanding aggregates

industry by allowing the company to increase productivity, cut down

repair time and costs, as well as save £3,000 through the elimination of

unplanned failures.

A major steelmaking company was facing high machine maintenance

costs. After inspection, the customer was recommended to replace

the previous bearings being used in its industrial furnace with SKF’s

specially developed high temperature bearings. The high temperature

bearings have been developed to operate trouble free at high

temperatures due to a graphite-based lubricant that does not lose its

lubricating properties; this eliminates the risk of metal-to-metal contact

as well as the need for re-lubrication to ensure a long and reliable

service life. The new bearings, once installed, helped the customer

eradicate all temperature related bearing failures in the furnace and

consistently operated without fault. The switch resulted in instant

performance improvements, cost savings of up to £6,000, and proved to

be environmentally friendly with reduced grease consumption.

www.skf.co.uk

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Case Study 1

Case Study 2

Amount Saved

Amount Saved

Product

Product

Industry

Industry

£648,880

£240,000

Deep Groove Ball Bearing with DDU Sealing

VV Sealed Deep Groove Ball Bearing

Construction

Food and Beverage

A market leading manufacturer of insulation products for the

construction industry had recently completed commissioning of a new

automated line. Production was reported as being erratic due to the

repeated failures of bearings used on the blade guide rollers of the

band saws. The situation became critical with bearings sometimes only

lasting for three hours and daily bearing changes becoming necessary.

The impact was costly downtime and an increased maintenance cost.

Engineers performed a failed bearing analysis at the site and identified

bearing failure due to ingress of contamination as the problem. The

alternatives recommended by the team were Deep Groove Ball bearings

with high performance NSK DDU sealing, using a patented triple lip

mechanism. A trial showed an immediate significant improvement in

bearing life and cost savings of £648,880 for the customer.

The world’s largest can manufacturer was experiencing regular,

unexpected, production stoppages due to premature failure of the

bearings fitted to the spray head inside coating machines. This caused

significant disruption to production and high downtime costs. A full

evaluation of the application was conducted, including a grease analysis

which revealed that the bearings were seizing due to grease being

ejected from the bearing by high pressure air that was needed for the

process. The team proposed NSK non-contact VV seals together with

a change to bearing geometry resulting in good grease retention, an

increase in bearing life from seven days to 110 days in operation, and

cost savings of up to £240,000.


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Case Study 3

Case Study 4

Amount Saved

Amount Saved

Product

Product

Industry

Industry

www.nsk.com

£38,400

£12,139

Molded-Oil bearings with DDU Seal

Life-Lube® with Molded-Oil Insert

Cement

Food and Beverage

A customer was experiencing repeated bearing failure on the blade

support of a concrete pipe slotting machine; every two to three months

they would experience up to eight hours downtime which led to

increased maintenance costs. A failed bearing analysis was conducted

to conclude that ingress of cement dust was contaminating the grease

which was causing the failure. An application review showed that the

existing bearings were inadequate for the application, and new NSK

Molded-Oil bearings with a DDU seal were recommended instead. A trial

conducted with the new bearings proved to be immensely effective with

no failures in a 12 month time period. The switch to the recommended

bearings resulted in improved productivity, zero down time, and provided

the customer with €£38,400 in cost savings.

A premium vegetable processing company was experiencing frequent

bearing failure on a vegetable waste application causing significant

downtime and reduced production. A bearing failure analysis revealed

bearing seizure due to water and hard particle ingress leading to a

significant reduction in bearing life. A trial was conducted with the

recommended NSK Life-Lube® with Molded-Oil inserts to demonstrate

not only improved bearing life but also reduced downtime, and

maintenance costs as well as increased productivity.

The NSK Life-Lube® and Molded-Oil inserts dramatically increased

the bearing life from one month to over 12 months, and the company

achieved cost savings worth £12,139.

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Case Study 1

Case Study 2

Amount Saved

Amount Saved

Product

Product

Industry

Industry

£36,500

£19,550

Product Cylindrical Roller bearings

Technical Advice

Metal

Cement

A metal mill client was experiencing bearing failures every two to

three months. Brammer was contacted to help find a solution after

even alternative products did not improve the situation. Following an

assessment visit, Timken’s Cylindrical Roller Bearing proved to be

the fastest and easiest bearing to fit. This was a new application for

the bearing and in addition to supplying the bearings, the customer

also asked for yearly inspections to be carried out. The customer also

benefited from Brammer’s invaluable advice on bearing maintenance,

sealing and lubrication. The mill has now shifted to running a full

complement of Timken bearings and the customer is now enjoying a

bearing life of over five years resulting in significant ongoing

cost savings.

The customer was facing difficulties with bearings on Gencor screen,

and as a result was replacing them every six weeks, leading to high

costs and downtime. Brammer was contacted to examine why

the bearings were consistently failing and offer technical advice to

structure an improved maintenance plan. An engineer visited the site

and prepared a report advising suitable recommendations; suggesting

to switch from the current mineral 100 oil in use to fully synthetic

CLP150 and to fit a temperature indicator close to the bearings to help

monitor the temperature. With regard to general running conditions, he

suggested trialling a bearing with C3 clearance which would be slightly

tighter in application. Two years later, the bearings are still operating

without issue.


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Case Study 3

Case Study 4

Amount Saved

Amount Saved

Product

Product

Industry

Industry

www.timken.com

£75,000

£73,420

Workroll Bearing

Solid Block Housed Unit Cement

Metal

As part of Brammer’s annual inspection programme at one of their metal

working clients, the workroll bearings, chocks and roll necks were all

inspected. The measurements taken during the inspection identified

uneven wear on the bearings resulting in the need to replace bearings

more regularly. Recommendations by engineering teams from both

Timken and Brammer were made to swap the bearings around periodically

to achieve more extended life with each bearing. Timken roll neck grease

was also suggested to help maintain the chocks and roll necks, whilst

taking further measures to avoid scoring. The recommendations provided

by the engineers not only helped to increase the bearing life, but also

helped reduce cross rolling which in turn improved the work roll bearing

life. The savings were realised as replacement bearings were needed less

frequently resulting in savings of around £75,000.

A customer asked for advice on identifying new bearings that would

last longer, together with housing that would be easier to change to

increase performance. The customer had been experiencing significant

downtime as existing bearings were failing due to ingress and required

replacing every 3 months. The existing blocks also took two hours to

change resulting in a large impact on lost stock. Following a visit from

Brammer’s Centre of Excellence the customer’s existing bearings on

their C2 Conveyor were replaced with a solid block housed unit. The

new bearing has been running for over a year, with no issues. As well as

a much longer bearing life the fitting times were also reduced to half an

hour per unit.

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Case Study 1

Case Study 2

Amount Saved

Amount Saved

Product

Product

Industry

Industry

£1,769,000

£90,769*

Split Spherical Roller Bearing and Spherical Roller Bearing

Spherical Roller Bearing with Medium-frequency Inductive Heating

Steel

Oil & Gas

One of the biggest steel manufacturers in the world suffered from an

unexpected, sudden main trunnion bearing failure and the resulting loss

of operation could mean a significant loss in revenue. After consultation,

a method statement was drawn up to specify the sequence and method

to replace the failed bearing to the customer’s requirements. It was

recommended that the customer use a special FAG split spherical

roller bearing as a spare in order to reduce downtime as well as a solid

spherical roller bearing. The work, and unexpected problems that arose,

were all completed within ten days resulting in potential cost savings

equivalent to £1,769,000. The customer was also supplied with a

practical maintenance schedule to guide them after installation.

A world leading company for subsea engineering and construction had

to replace an existing starboard reel bearing after highlighting a static

fault during a condition monitoring test and examination of the outside

diameter of the journal. Their requirement was to minimise the time

the vessel was in port, so they turned to expert guidance. In order to

save time, the bearing was heated using a medium-frequency device,

and bespoke mounting and dismounting tools were used to ensure

accuracy and safety of re-build. To guarantee the operational integrity

of the replacement bearing, condition monitoring measurements were

also conducted. By using specialist skills, the customer benefited

from the broad bearing and service knowledge of a leading bearing

manufacturer, and also reduced the time needed in port by one day

saving themselves approximately £90,769.

*Converted from Euros using conversion rate of £1=€1.3

These savings are dependent upon throughput and steel grade mix.


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Case Study 3

Case Study 4

Amount Saved

Amount Saved

Product

Product

Industry

Industry

www.schaeffler.co.uk

£116,540*

£38,460*

Split Spherical Roller Bearing

Spherical Roller Bearings with TRIONDUR Coated Rolling Elements

Cement

A global company that offers worldwide solutions to all construction

industries had been experiencing failure of standard roller bearings in the

conveyor belt which would cause downtimes of at least 22 hours. After

an analysis they were offered the solution to shorten replacement time

and consequential economic losses simply by using split spherical roller

bearings which could be mounted into the existing housings without

major dismounting work. The new split bearings not only considerably

reduced downtime, simplified mounting and reduced assembly and

maintenance costs but also resulted in £116,540 of cost savings.

The simplicity of the solution makes it ideal for all customers with the

same application.

A customer was experiencing problems on a paper machine which

produced wood-free fine paper grades with an annual capacity of

approximately 230,000 tonnes. The calender on the machines consisted

of two pairs of rollers that were arranged one behind the other. In the top

roll position, a combination of low loads of the spherical roller bearings

and insufficient lubrication would cause damage to the raceways. The

customer asked for help to reduce the risk of bearing slippage, and

the risk of slippage damage. After inspection, thermo rolls with FAG

spherical roller bearings with TRIONDUR coated rolling elements was

offered as the perfect solution.This would not only ensure a longer life,

but also prevent bearing damage even in sliding friction conditions. As a

result, the customer saved £38,460.

Pulp & Paper

*Converted from Euros using conversion rate of £1=€1.3

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Case Study 1

Case Study 2

Amount Saved

Amount Saved

Product

Product

Industry

Industry

£4,500

£50,000

Split Roller Bearings

Stainless Steel Split Bearing

Chemical

Gas to Liquid

A UK fertilizer company was facing regular bearing failure when

preparing its ammonium nitrate by using a twin-screw mixer resulting

in costly downtime. Solid spherical bearings replacement was

taking up to five hours, along with creating health and safety issues.

After assessment, it was suggested that they move to using a set

up comprising of a custom built ‘tandem’ housing unit to hold two

bearings, Cooper split roller bearings and high-temperature packing

seals. The solutions offered many benefits including reduced downtime

to only one hour, the capability of changing the split bearings without

removing couplings, less exposure of fitters to hazardous conditions and

estimated cost savings of £4,500 at every change.

An important gas to liquid processor asked Cooper experts to identify

a bearing solution that would be resistant to corrosion. Their current

belt and scroll conveyor bearing housings was made of cast iron and

needed replacing every few years due to severe corrosion in a salty

humid, environment. The customer wanted to keep their split roller

units maintenance cost savings, due to easy access during repair.

After looking at several possible solutions the engineers recommended

bearing housings in stainless steel grade 304. Both the outer housings

and the inner cartridges were then manufactured in this material, along

with blanking plates and other exposed parts which increased housing

lifetime and led to further dramatic maintenance cost reductions.


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Case Study 3

Case Study 4

Amount Saved

Amount Saved

Product

Product

Industry

Industry

www.cooperbearings.com

£10,000

£5,000

Expansion Bearings and GR Fixed Bearings

Grease Lubricated Bearings

Animal Feed

A feed mill was incurring high costs for a crane hire to undertake

maintenance on its own elevator which required removal of the roof. The

previously fitted bearings on the bucket elevator had drive shaft bearings

fitted in trapped applications behind a gear reduction box, which caused

immense maintenance access problems. The rusty mill environment also

had a negative impact on the lubrication and life of the bearing. Keeping

in mind the nature of the elevator cladding, they were advised to use

Cooper expansion and GR fixed bearings with felt seals to prevent

the ingress of abrasives, and reducing grain dust. It also allowed the

customer access for maintenance and inspection at any time without

undergoing expensive removal of the mill roof.

A reputed deep coal mine operator was facing problems with its sleeve

bearings in the radial fans; they were leaking oil, partly owing to the

abrasive environment and failing to achieve their specified lifetime.

After an analysis, experts suggested specialised EX and GR grease

lubricated bearings. As a result, complex oil feed and cooling systems

were no longer required which not only eliminated the risk of bearing

failure seizure, but also oil leaking and further provided a cleaner and

safer work environment. The switch also eliminated costs associated

with continuous lubrication and maintenance, as well as significant

energy savings.

Coal

National Distribution CentreHeadway RoadWolverhamptonWV10 6PZ

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www.brammer.co.uk

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Delivering Cost Savings - Brammer Bearings Brochure - Jul 2016... · bearing suppliers; SKF, NSK,...

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Transcript of Delivering Cost Savings - Brammer Bearings Brochure - Jul 2016... · bearing suppliers; SKF, NSK,...