Waste Treatment Application
CASE 1: Pump impeller - sewage treatment
| BEARING TYPE: |
Roller bearing, #23052 |
| CONDITIONS: |
Sewage in oil bath. |
| RESULTS: |
Service life increased 300%, with reduced labor costs by decreasing maintenance schedule from 6 months to 18 months. The potential of contaminating local waterways was reduced, helping to avoid incurring fines of $100,000 per occurrence. |
Power Generating Application
CASE 2: Coal pulverizer grinding wheel
| BEARING TYPE: |
Tapered roller bearings, HH249910/HH249949 & EE350750/EE350351 |
| CONDITIONS: |
Coal dust caused bearing seizure, resulting in the dust being ignited. Bearing life 9 months. |
| RESULTS: |
Used in addition to conventional lubrication, MicroPoly has kept contaminants out of the bearings. Life of the oil bath has increased two-fold and is now changed out every six months. Bearing life has been extended to 10 years. Maintenance related downtime has been substantially reduced, with annual cost savings of $250,000. |
Wood Product Applications
CASE 3: Idler bearing in 120 roller chain sprockets in forest products machinery, slicers, feeders & bar
screens
| BEARING TYPE: |
5208EENR, double row ball bearings
|
| CONDITIONS: |
Water, chips, dust and dirt penetrated the bearings. Bearing life 4 weeks.
|
| RESULTS: |
Bearing life has been extended from 4 weeks to over 4 months.
|
CASE 4: Baghouse dust conveyor bearings - wafer board manufacturer
| BEARING TYPE: |
Flanged ball bearing units, 2-15/16” bore
|
| CONDITIONS: |
Wood dust and atmospheric humidity. Bearings changed every 3 months. Bearings are outside and exposed to moisture. Speed 600 RPM. |
| RESULTS: |
Bearing life has been extended to over 1 year. |
Earth Moving Application
CASE 5: Trenching equipment
| BEARING TYPE: |
Guide wheels and idler wheels, 22308 spherical roller bearing (axle bearing), FYRP 2-1/2” roller bearing |
| CONDITIONS: |
Trenchers run in dusty, dirty, muddy conditions. Dirt and mud are pulled up and packed into the housings around the bearings. Idler wheels and axle bearings were replaced every month. Roller bearings were replaced every 2 months. |
| RESULTS: |
Idler wheels and axle bearings filled with MicroPoly have been in service for almost a year. Life of the FYRP roller bearings was extended from 2 months to 2 years. |
Cement & Ceramic Applications
CASE 6: Packer head (hydro tile) – concrete pipe manufacturer
|
BEARING TYPE: |
Fafnir 1106KKR, 1108KKR, 1203
|
|
CONDITIONS: |
Sand and concrete contamination. Bearings are outdoors. Bearing life 1-2 days. Speed 100 RPM. |
|
RESULTS: |
Discontinued monitoring after 6 weeks. Results exceeded expectations. |
CASE 7: Depalletter, telescoping section
| BEARING TYPE: |
Needle roller bearing, 1-3/4” - GR 32 – GR 40 |
| CONDITIONS: |
Concrete dust contamination. Bearing life 3-4 months. Speed 178 RPM. |
| RESULTS: |
Bearing life extended to at least 2-1/2 years. |
CASE 8: Painting spindle bearing – ceramic plate manufacturer
| BEARING TYPE: |
R6ZZ single row ball bearing |
| CONDITIONS: |
Paint and solvents contamination. Bearing life 1-2 days. Speed 5-10 RPM. |
| RESULTS: |
Bearing life has been extended to at least 30 days. |
Chemical Applications
CASE 9: Dragline – vertical rotating shaft; lower bearing – fertilizer plant
| BEARING TYPE: |
Spherical roller bearing, #22315 |
| CONDITIONS: |
Dirt and gypsum contamination. Bearing life 1-1/2 months. |
| RESULTS: |
Bearing life has been extended to over 1 year. |
CASE 10: Lamination line – foam plant
| BEARING TYPE: |
McGill cam follower
|
| CONDITIONS: |
Required manual greasing that involved shutting down the equipment/line for at least 5 hours. Bearing life not a primary consideration. |
| RESULTS: |
Manual greasing is no longer required. Downtime due to manual greasing has been eliminated, resulting in substantial cost savings. |
Fastener Application
CASE 11: Transfer application
| BEARING TYPE: |
61902 & 61903, single row ball bearings |
| CONDITIONS: |
Dirt and contaminated oil penetrated the bearings causing premature failure. |
| RESULTS: |
Bearing life has been extended 3 fold. |
Dam Application
CASE 12: Floodgate actuators
| BEARING TYPE: |
30210 tapered roller 2-1/2” bore |
| CONDITIONS: |
Actuators sit in moisture and corrosive environment for long periods of time between uses. Bearings corrode causing inaccurate positioning of gates and relay signals for closure. |
| RESULTS: |
80 bearings are in test. During visual checks, corrosion levels appear to have been reduced. |
Wire Drawing Application
CASE 13: Wire drawing – bottom of wire reels
| BEARING TYPE: |
Single row ball bearing, 6204
|
| CONDITIONS: |
Fines from the copper wire were getting into the bearing, causing bearings to fail in 2 months. |
| RESULTS: |
Bearing life has been extended to 6-8 months.
|
Mattress Manufacturer Application
CASE 14: 4300 Gribitz sewing machine
| BEARING TYPE: |
Cam Followers
|
| CONDITIONS: |
Manual lubrication of cam followers caused grease and oil to get on the bed material. This caused staining, which resulted in loss of product. |
| RESULTS: |
MicroPoly has stopped the lubrication staining, thus eliminating the need to scrap bed material due to staining from grease and oil. |
Agriculture Application
CASE 15: Disk harrow
| BEARING TYPE: |
Pillow block |
| CONDITIONS: |
Water, dirt, and mud. Bearings are outside. Bearing life varies. |
| RESULTS: |
Bearing life extended at least 3 fold. |
CASE 16: Automated mulch
bagging
| BEARING TYPE: |
20
mm single row ball bearings |
| CONDITIONS: |
Bearings exposed to grit, moisture, and heat from bag sealers.
Bearing life was 6 months. |
| RESULTS: |
Bearings
were filled with MPI-0779. Bearing life extended to 18
months so far. |
Petrochemical Application
CASE 17: Top feed roll
| BEARING TYPE: |
Self-aligning ball bearing |
| CONDITIONS: |
Bearings were running in a wet environment. Bearing speed 1,100 RPM. Temperature 130-140°F. Bearing life 2-3 weeks. |
| RESULTS: |
MicroPoly filled bearings have been running for 3 months so far with no failures. |
Aggregate Application
CASE 18: Head & tail shaft pulleys in metal processing/mining
| BEARING TYPE: |
Rexnord, 2-15/16” bore |
| CONDITIONS: |
Sand and water contamination. Bearing life 3 months. Speed 850 to 1370 RPM. |
| RESULTS: |
With MicroPoly, bearing life has been extended to at least 18 months.
|
Textile Application
CASE 22: Manufacturer of roofing products
| BEARING TYPE: |
Sealmaster NP 16 1-3/16” |
| CONDITIONS: |
Paper goes through the looping line where tar is applied. The tar contaminates the bearings and normal life for a greased bearing is one week. |
| RESULTS: |
With MicroPoly installed, the bearings are still running after four weeks.
|
Plastic Application
CASE 25: Chain guide for “puller block” in conjunction with extruder
| MICROPOLY: |
1” x 2” x 12” chain lube block |
| CONDITIONS: |
Frictional heat on expensive profiled UHMW chain guide caused softening of guide and replacement of 40 blocks, 2 or 3 times per year. |
| RESULTS: |
Customer cuts MicroPoly blocks into 6” lengths and machines sides down to provide two raised shoulders. MicroPoly has doubled the life of the UHMW. Change out on the guides had cost customer $500 per block. 40 blocks x 2 changes per year saved $20,000. |
Aggregate Application
CASE 26: Trunion scrubber for asphalt
| MICROPOLY: |
Solid profile installed in metal plate |
| CONDITIONS: |
The surfaces had to be greased daily and, if not, metal would wear out and cause trunion to track off and shove bearings out of their housings. |
| RESULTS: |
MicroPoly has been installed 3 months. No additional lubrication needed. Labor savings has been substantial. |
Furniture Manufacturing Application
CASE 27: Wood board conveyor
| MICROPOLY: |
Conveyor chain lubrication, #80 chain, 50’ long, and 24’ center distance with 8” sprockets |
| CONDITIONS: |
Chain moves 1 revolution every 2 minutes. Manual greasing of chain required every 4 weeks. This manual greasing contaminated the boards and dripped grease onto the floor, creating safety and housekeeping problems. |
| RESULTS: |
MicroPoly blocks have been in place 6 years and are still in operation. Manual greasing has been eliminated, thus, solving the safety and housekeeping problems. |
Waste Treatment Application
CASE 28: Sludge life chain
| MICROPOLY: |
MicroPoly 1” x 2” x 8” lubrication block is used to lubricate conveyor chain |
| CONDITIONS: |
Water and dirt get into pins. Chain life is very short. Application is indoors. |
| RESULTS: |
Results are very good. All conveyor chains are now lubricated in this manner. |
|
