When food safety is your concern, EDT bearings are your best choice

EDT Bearings

At OTP, we understand your food or beverage plant needs to have very little downtime for maintenance. For more than 35 years, EDT Corp. has designed and manufactured mounted and unmounted bearings for virtually all areas of the food processing floor.

Low-maintenance plane bearings with reusable components

EDT’s signature plane bearings (including Poly-Round® Solution® bearings) retrofit industry standard bearings and are:

  • USDA-accepted
  • Grease-free and rust-free
  • Chemically resistant
  • Unaffected by process moisture
  • Contain no rolling elements, eliminating catastrophic failure

Poly-Round® bearings can also be rotated 180 degrees and re-inserted after they’ve been worn in one direction. This effectively doubles their useful life. And because wear can be measured and monitored with all EDT plane bearings, change-outs can be scheduled.

Reduced risk of food contamination

EDT’s new Metal Detectable Poly-Round® decreases the chance of costly food contamination incidents. Its material is designed to be detected in three ways: metal, x-ray and optically detectable.

EDT’s stainless ball bearings use either food-grade grease or food-grade solid lubrication.  They’re available in shaft sizes from 1/2 to 3 inches (12 mm to 70 mm), including sizes not available elsewhere. Stainless ball bearings are preferable for applications where plane bearings don’t perform as well, such as high speed and high tension environments.

Reusable bearing housings to decrease operating expenses

EDT housings are available in all styles and in three types of materials: machined stainless, production stainless and polymer (including optically detectable blue housings).  Both the machined stainless and polymer materials are USDA-accepted, and all are designed to maximize clean-ability. All housings are available in QuiKlean® design, featuring an integral standoff, 5/8 inch above the base, further improving sanitation and clean-ability. Finally, all EDT housings can be reused, reducing operating expenses.

Whatever your applications throughout the process floor, EDT has the right bearing for the job. For more information on EDT bearings, contact an OTP expert today!

Choosing the Best Bearing for your Application

Mounting and installation errors are the second-leading cause for bearing failures — accounting for almost 27% — and generally result in production downtime and increased cost. It should come as no surprise that not all bearings are created equal, and choosing the best seal and shaft locking mechanism for your bearing will increase the overall performance and life.

Reduce Downtime

 When selecting your next bearing, determine if the application has:

  • High speed
  • High contamination, or
  • High heat

Each of these conditions requires a specific seal to obtain maximum performance. Most importantly, applying the correct seal will result in a reduction in downtime.

  • Clearance seals: High-temperature and high-speed capabilities; contamination prevention is low
  • Light contact seals: Moderate temperature capability, high-speed capability and good contamination prevention
  • Heavy contact seals: Moderate temperature capability, very low-speed capability; best option to prevent contamination
  • Auxiliary seals: Best option to maximize bearing protection and life when combined with other seals

Increase Performance

When it comes to getting a job done, performance is key. In addition to applying the correct seal, there are several shaft-locking mechanisms to consider:

  • Set screw/set collar: Works great in most applications but may come loose under high load or speed, or if shaft is slightly undersized
  • Eccentric collar: Slightly better than a set screw; tightening direction is critical
  • Concentric clamping: Provides great holding power, does not damage the shaft and reduces vibration
  • Tapered adapter: Provides excellent grip force, the best concentricity, low vibration and the longest life

Choosing the best bearing for your application is just the first of five important tips for successful bearing installation. Learn how to install your bearings correctly the first time by accessing Rexnord’s free, expert-led webinar hosted by Mark Czubak, principal engineer for bearings at Rexnord.

For more information about specific bearing products, contact an OTP expert today!

 

Considerations When Purchasing Rexnord Filament Bearings

 

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Our partners at Rexnord Corporation address common questions our customers have when purchasing bearings, such as Rexnord’s filament bearings. What is a filament bearing? When would you use one? OTP Industrial Solutions and Rexnord team up to help our customers make an informed purchase decision.

 

What is a filament bearing? 

“Filament” is a general term to designate filament wound, non-metallic composite bearings. The structure of the filament bearing should be reinforced with continuous filaments of fiberglass or another material helically wound around a mandrel.

 

When should you use a filament bearing?

Among the most common filament bearing applications are agricultural machinery, construction equipment, energy processing equipment, food and beverage processing equipment, forest product processing equipment, hydraulic and pneumatic cylinders, lift systems, material handling machinery, mining equipment, recreational vehicle clutches, sailboats, stern drives, and water management valves and actuators.

When considering filament bearings, keep in mind that straight sleeve configurations work well in oscillatory (pivoting), linear sliding and slow-speed full rotation applications like those found in recreational vehicle clutches, construction equipment and water management butterfly valves. Hex and square bore configurations are used in applications such as agriculture and wood processing equipment. These configurations provide torque transmission or prevent shaft rotation, while allowing linear motion. Linear configurations work well in harsh applications like contaminated or wash-down environments, as well as food packaging machinery and factory automated production lines.

 

When considering your filament bearings, keep in mind the importance of:

  • Self-lubricating features that reduce maintenance time
  • Corrosion and moisture resistance, meaning they can perform when submerged in fresh or salt water
  • Non-metallic composite material that will not seize to a shaft
  • Non-metallic options that could be up to 77 percent lighter in weight than steel bearings and 30 percent lighter than aluminum bearings
  • Electrical insulation

 

Contact us today to learn more about Rexnord filament bearings and get the answers to all of your bearings questions.

 

Identifying and Preventing Bearing Failure

By Rexnord Corporation

Rex 6000 Series SHURLOK Adapter Mount Roller Bearings
Rex 6000 Series SHURLOK Adapter Mount Roller Bearing

Improper installation causes an estimated 27 percent of all bearing failures, making it one of the leading causes of unplanned downtime and lost productivity for many end users. Many users will over-tighten a bearing, thinking the harder they torque a bearing onto the shaft, the better the performance. Unfortunately this is not the case, as over-tightening a bearing can reduce internal clearances and cause a bearing to overheat during operation and fail prematurely.

Likewise, if a bearing is not securely affixed during installation, the shaft can slip within the bearing, causing excessive wear, vibration and ultimately failure. To avoid setting and adjustment errors when installing a bearing, you can use feeler gauges to judge proper installation based on internal clearances.

Rexnord® recognizes that replacing bearings on equipment should be straightforward and error-free, so it offers patented shaft attachment options to improve shaft holding force and simple installation.

Rexnord SHURLOK® Bearings help solve installation problems with Spyglass Optical Strain Sensor technology, which shows the installer when the correct tightness is achieved through a color change, taking the guesswork out of installation. Also, the Rex® 6000 Series SHURLOK Adapter Mount Roller Bearing requires less lubrication and is ideal for ISO 14000 compliance.

To learn more about SHURLOK Bearings, contact an OTP expert.

Optical Strain Sensor technology in SHURLOK bearings
Optical Strain Sensor technology in SHURLOK bearings changes color to tell the installer when the bearings have been correctly tightened to the shaft.

 

 

OTP Industrial Solutions Becomes Premier Distributor for EDT Bearings

Bearings for Severe Service Environments

EDT Bearings
EDT Bearings

OTP Industrial Solutions has become a Premier Distributor for EDT Corp. As a Premier Distributor, OTP has local inventory of an array of EDT bearings to respond immediately to customer requirements. The OTP sales staff has had EDT product training, so they can provide knowledgeable service and support to all their industrial customers.

EDT Corp. is a 35-year-old bearing manufacturer that specializes in severe service bearing applications. EDT’s grease-less, low-maintenance products are designed to operate in extreme environments while providing customers with reliable bearing life and performance. In addition, many of EDT’s products are USDA-accepted.

Think “EDT bearings” for any application where traditional bearings don’t operate well:

  • If you are changing a bearing more than once a year
  • If you are greasing a bearing at least once a week
  • If wash down or chemicals prematurely fail a bearing
  • If food safety or product contamination is an issue when USDA or HACCP/HARPC programs are in place

For more information, please visit www.edtcorp.com.

High Expectations for Gearbox Bearing Lives

By Frank Klein, Senior Engineer, Rexnord Corporation

“High Expectations for Gearbox Bearing Lives” reviews different methods for calculating bearing life and their implications, the validity of traditional approaches for calculating bearing lives, and provides a general overview of bearing life expectations.

The following is a summary of a white paper that reviews different methods for calculating bearing life and their implications, the validity of traditional approaches for calculating bearing lives and provides a general overview of bearing life expectations.

Bearing specifications are written by companies for the purpose of defining anticipated machinery performance.

The traditional approach in writing such specifications for anti-friction bearings has been to request “calculated bearing life” for an L-10 life of 50,000 or 100,000 hours, as examples, based on a five- or ten-year operating life before “major repairs” are required. The L-10 bearing life is naturally understood to be a bearing’s defined life expectancy based on a statistical 90 percent reliability.

To achieve such values, calculation methods have become more and more sophisticated. Traditionally, calculating L-10 was a matter of knowing the speed of the bearing (cycles), taking the equivalent load on the bearing and comparing it to the bearing’s dynamic capacity.

Today it is common practice to calculate an adjusted L-10, which takes the traditionally derived results and allows for the influence of various operating parameters.

With the base L-10 calculation, everyone gets the same answer – which is not the case with adjusted L-10 calculations.

The predicament for the specification writer therefore becomes twofold:

Predicament #1: Given that an L-10 values has to be specified, what is a reasonable value?

Predicament #2: Given that adjusted L-10 calculations can sometimes appear to be a function of the wizard behind the curtain, how can one judge the validity of the lives calculated?

Click here for a detailed white paper that addresses the questions in this blog post.

The fact is that simply specifying an L-10 value may not achieve the intended purpose of machine life expectations.

How does one judge which adjusted L-10 calculation is closest to the intent of the specification?

  1. Ensure that the L-10 requirement is consistent with the rest of the specification. Calling for a gearbox 1.5 service factor, for example, but a minimum 100,000 hour base L-10 means the selection is driven by the L-10 requirement. Unless the item is a specialty design, the features are designed for economic competitiveness, and the bearing life comes along for the ride.
  2. Make sure the load base is clear by having everyone calculate base L-10 on motor and Normal Running Load (NRL). Consider that the catalogued design non-adjusted L-10 life of most industrial gearboxes is less than 5,000 hours based on a mechanical SF of 1.0. For example, getting 100,000 hours requires an impossible adjustment factor in relation to the 1.5 SF on the gearing.
  3. Apply limits that can be used for the various factors, as that creates a level playing field for everyone responding to the RFQ. For examples for lubrication (initial oil viscosity and nominal and nominal sump temperature) allows a maximum of, say, 2.5.
  4. Use a factor of 1.0 for oil cleanliness, as this takes initial and operating cleanliness into account and does not get into discussions of “initial start-up damage” or “filtration healing.”
  5. Allow a load zone factor only if detailed Finite Element Analysis (FEAs) were performed with conclusive deflection results — especially for prescribed variable loading conditions (histograms). Such an approach will be expensive as the supplier may be exposing proprietary design details. However, interpolations or extrapolations of a general design method would not qualify, as their validity could not be confirmed.
  6. Make sure that there are features, i.e. physical means, of getting to the assumptions that make sense.

When specifying anti-friction bearing life for any piece of equipment, the writer of the specification assumes a purpose (or purposes) for targeting a particular value. Once a value has been defined, it is of the utmost importance that the specification writer defines the loads, operating conditions, methods of calculations, and even values for particular factors in the calculations, in order to help assure accuracy and integrity of the claimed values that will be offered.

Additionally — and this is the critical overall systems-purpose for the specification — with the interpretive ability to understand what calculated bearing lives can and cannot guarantee, the author of the specification can outline a clear road map for associated functions, such as initial design, manufacturing, maintenance, and warranty, to meet the high expectations of specifying a particular L-10 life for the equipment.

Frank Klein originally delivered a presentation on this topic at the 2014 Society for Mining, Metallurgy & Exploration (SME) Annual Meeting & Exhibit for professionals.

Rexnord Senior Engineer Frank Klein, author of “High Expectations for Gearbox Bearing Lives,” originally delivered a presentation on this topic at the 2014 Society for Mining, Metallurgy & Exploration (SME) Annual Meeting & Exhibit for professionals.
Rexnord Senior Engineer Frank Klein, author of “High Expectations for Gearbox Bearing Lives,” originally delivered a presentation on this topic at the 2014 Society for Mining, Metallurgy & Exploration (SME) Annual Meeting & Exhibit for professionals.


NSK’S ASSET IMPROVEMENT PROGRAM SAVES MANUFACTURER OVER $80,000

From the NSK Americas Blog

We were approached by a cereal manufacturer who was concerned with the frequency that their production needed to be stopped in order to maintain their cereal bagging machinery.

Once a month, this particular manufacturer needed to stop production due to cereal dust entering the carriage of the linear guide and causing the rails to fail.

NKSK Asset Improvement Program

After completing Stage One of our Asset Improvement Program (AIP) Value Cycle (Situational Analysis), we proposed installation of our K1™ Lubrication Unit, which not only lubricates with maintenance free operation but also acts as a seal to help keep out debris. This particular product ensures that fresh, continuous oil flows onto the rail or shaft during operation, which in this instance helps to keep the bagging machine from suffering from cereal dust build up.

ADDITIONAL PRODUCT FEATURES AND BENEFITS INCLUDE:

  • Long-term, maintenance free operation
  • Effective in any mounting orientation
  • Up to 25,000 km without maintenance
  • Ideal for environments where grease replenishment is undesirable or where grease is easily washed away
  • Available on standard NSK linear guides, ball screws, linear actuators and robot modules

Through NSK’s expertise and innovative product line, the company was able to save $81,780 in annual maintenance.

ABOUT NSK

NSK is a global supplier of roller bearings, ball bearings, linear motion and automotive components with domestic and overseas manufacturing capabilities. For more information, visit http://www.nskamericas.com/.

OTP VENDOR PAGE

NSK

OTP Industrial Solutions thanks NSK for its great contribution to our Bearings blog.

ARE BEARINGS MAKING YOU SPIN YOUR WHEELS? 11 MYTHS THAT CAUSE BEARING FAILURE

By Ian A. Rubin, Emerson Power Transmission Solutions

The wheels of industry turn on bearings, so why do the wheels often vibrate, clatter, squeak, drag and overheat? Bearings can fail for lots of reasons. Most failures (as shown in Figure 1) are related to lubrication and contamination, but myths and misconceptions handed from one generation of maintenance engineers to the next help perpetuate many easily avoidable problems. These myths fall into three general areas of bearing use: installation, misapplication and lubrication.

Causes of Bearing Failure

INSTALLATION MYTHS

Installation myth #1: It’s okay to hammer a bearing into position if needed – FALSE.

Never strike a direct blow to a bearing. The rolling elements and raceway are hardened, but can still be damaged. A hammer blow can leave dents in the raceway that can cause noise and dramatically reduce bearing life. If installation is difficult, first check the shaft diameter; look for burrs, dirt or corrosion on the shaft. If needed, use a press to slide the bearing on. Apply pressure equally on the face of the inner ring to avoid damaging the raceways and rolling elements.

Installation myth #2: Off-the-shelf TGP shafting is the best option – FALSE.

It’s much more important to know the shaft’s tolerance range to be sure it meets your bearing manufacturer’s spec for diameter and roundness. Review the bearing manufacturer’s recommendations and measure/specify the correct shaft diameter.

Installation myth #3: It’s fine to hand-tighten setscrews one at a time – FALSE.

Setscrews should be tightened to the manufacturer’s recommend torque. Under tightening can allow the bearing to slip on the shaft. Over tightening can distort the raceway or crack the inner ring. Use the “half-full/full” rule for tightening setscrews – tighten the first setscrew to half the recommended torque, the second setscrew to the full torque, then go back to the first setscrew and apply full torque.

APPLICATION MYTHS

Application myth #1: Bearings should not be hot to the touch – FALSE.

Normal bearing operating temperatures can range from 80°F to 150°F, but certain applications may run higher or lower. Most bearings are rated for -20 to 220°F, but can be supplied with special grease, seals or heat stabilizing processes that allow them to operate at higher temperatures. Bearings normally run hotter at start up or right after re-lubrication because excess grease increases drag and friction in the bearing. Spikes up to 50°F are normal at start-up, and 30°F after re-lubrication. As the rolling elements purge excess grease through the seals, the bearings return to steady-state temperatures.

Application myth #2: Bigger bearings are always better – FALSE.

Bigger bearings with a higher load capacity may show a higher fatigue life, but if the load does not achieve the minimum requirement, the rolling elements can skid along the raceway instead of rolling. This can cause high temperatures, excessive wear, lubrication breakdown and bearing failure.

Application myth #3: Sealed/lubed-for-life bearings will last forever – FALSE.

Bearing life depends on grease life, which is affected by the operating conditions (speed and load) and environment (temperature and contamination). Grease life can be improved with enhanced seals, proper installation and proper grease selection. Ultimately, the best bearing is the properly lubricated bearing.

LUBRICATION MYTHS

Lubrication myth #1: Re-lubrication once a year is sufficient – FALSE.

Start by reviewing the bearing manufacturer’s lubrication recommendations. These will give amounts and intervals as suggested starting points, but actual lubrication intervals may vary quite a bit, depending on load, speed, temperature or environmental conditions. Applications with higher speeds, temperatures or heavy contamination sometimes require frequent re-lubrication, possibly weekly or daily. By contrast, a mounted ball bearing in a lightly loaded, low-speed, clean environment may do fine with re-lubrication at 12 to 24 month intervals. Certain applications may need to be monitored and lubrication intervals/amounts adjusted accordingly.

Re-lubrication replenishes grease when the current grease breaks down or deteriorates because the base oil breaks down due to temperature. Without this, the lubricating property is gone and the result is metal-to-metal contact. Re-lubricating the bearing replenishes the oil, maintaining the proper film.

Pumping new grease into a bearing also helps flush away contamination. Many mounted bearings are designed to allow grease to enter the bearing cavity as close to the rolling elements as possible. As more grease is added, the old grease is pushed out of the seals (if the seals are purgeable). The purged grease carries out contaminants and keeps dirt away from the seals.

Lubrication myth #2: Always add grease until it purges from the seal – FALSE.

If you pump grease into the bearing until it purges out the seal, you probably have completely filled the bearing cavity. Excess grease can increase operating temperature and may create enough pressure to blow the seal out.  However, in low-speed or dirty conditions where contamination may easily enter the seals, filling a bearing with grease may help improve performance. Application experience will dictate when the entire bearing cavity should be filled.

Lubrication myth #3: If a bearing makes noise, grease should be added – FALSE.

If a bearing is making noise, internal damage has likely occurred. This increases over time, with the potential for catastrophic failure. Adding grease may provide temporary relief, but a noisy bearing should be closely monitored and replaced at the first opportunity. The root of the failure should also be investigated either with independent or manufacturer failure analysis (manufacturer analysis requires removal of the bearing as soon as possible to aid in a more accurate diagnosis of the problem).

Lubrication myth #4: Any grease will do – FALSE.

Greases DO differ. Some may be incompatible because of the different thickeners (soaps) used. When two incompatible greases are mixed, they may thicken and harden or become thin and leak out of the bearing. For example, many electric motors use a polyurea thickener while some mounted ball bearings use lithium-complex thickeners. These greases are borderline compatible, and depending on the actual make up, may not work together. Grease types can also be incompatible based on the viscosity or type of oil in the grease, so consulting a lubrication supplier is always recommended.

Lubrication myth #5: Just shoot grease through the fitting – FALSE.

Always clean grease fittings and the grease gun tip. It’s good practice to put the grease gun tip in an oil bath or wrap it with a plastic cover to protect it.

Your plant’s uptime and OEE may “turn” on your bearings’ good health. If you are not achieving the desired operational life for some of them, a bearing manufacturer can assist you with proper selection and troubleshooting.

ABOUT THE AUTHOR

Ian A. Rubin is Director of Marketing, mounted bearings, for Sealmaster, System Plast and Browning-branded products at Emerson Power Transmission Solutions. For more information, visit powertransmissionsolutions.com.

OTP VENDOR PAGES

Browning Bearing
Sealmaster

OTP Industrial Solutions thanks Emerson Power Transmission Solutions for its excellent contribution to our Bearings blog.

SEALMASTER BEARINGS LOWER MAINTENANCE COSTS, PROVIDE LONGER PRODUCT LIFE

By Woody Schmetzer

When choosing the right bearing, cheaper is not always better—or even cost effective. A less expensive bearing typically means lower quality, additional bearing change outs and more bearing purchases. Even though the bearing is less expensive on paper, over time the costs can add up.

For example, OTP recently helped a customer with two bottling facilities lower its maintenance costs and improve its operations by choosing a product line that stood above the competition and was a great fit for our customer’s needs. Each of the customer’s plants experienced premature bearing failures and went through many pillow and flange block bearings, which we supplied to them for years. It reached a point where we needed to do something different to improve the bearings’ performance.

After analyzing our customer’s operations and unique needs, OTP technicians selected Sealmaster bearings. The Sealmaster bearing chosen for our customer handles loads better and provides enhanced lubrication, which results in longer bearing life. The Sealmaster bearing provides superior features:

  • Wider inner and outer races
  • Felt seal instead of rubber lip
  • Land riding metal ball retainer
  • Zone hardened inner race
  • Locking pin that allows grease to go directly into the insert bearing

Overall, switching our customer to Sealmaster bearings meant less maintenance and downtime from changing out worn bearings. Three years later, the Sealmaster bearings are still running strong inside our customer’s facilities.

Need an expert solution for your bearings? OTP Industrial Solutions is happy to answer your questions and ready to provide assistance for your industrial product needs. Contact an OTP Sales Engineer for more information.

SEALED BALL BEARINGS RUNNING HOT? CONSIDER USING NON-CONTACT SEALS

By Dave Deetz

A sealed ball bearing is probably the most commonly used bearing in the world. They are designed for industrial machines, appliances, electric motors, pumps, gearboxes and conveyors . . . just to name a few applications. Most sealed bearings incorporate two contact seals. These seals (usually nitrile rubber) are positively engaged in the outer ring and then rub against the inner ring producing a positive contact seal. This seal rubbing produces friction and heat and is the reason the bearing RPM rating must be reduced. A sealed bearing is often rated at only 65% of the RPM for an open or shielded bearing.

A non-contact seal might be a good choice to consider. This type of seal is also positively engaged in the outer ring, but the bearing inner ring incorporates a “V” shaped cut. The bottom of the non-contact seal is formed in the same shape. This produces a labyrinth seal to protect the bearing. But this seal does not make a positive contact with the inner ring, so there is no reduction in the rated RPM and no increase in bearing operating temperature.

The non-contact seal has become very popular where higher bearings speeds are found like the electric motor industry. NTN (LLB seal) and NSK (VV seal) have become industry leaders with non-contact seals.

Are non-contact seals a good choice for applications in your plant? Call an OTP Sales Engineer to receive help with your bearing selection. OTP Industrial Solutions’ team of bearing experts has the knowledge, training and experience to find the right bearing for any application. Please call or email us with your request.