Cost-Effectiveness of an Automatic Lubrication System for Bearings

Abstract

Improper lubrication is a leading cause of bearing failures, accounting for half of all instances. Lubricating bearings with grease or oil forms a protective film that prevents direct metal-to-metal contact, reducing friction and overheating, and prolonging the bearing’s lifespan. Lubrication also acts as a barrier against foreign particles and wear. In this study, an analysis of automatic lubrication in a milling plant was carried out and compared to manuel lubrication. A milling factory with 22 roller mills with a total production capacity of 450 tons/day is considered. It is calculated that the failure of eight bearings in each mill roller due to lubrication issues results in a substantial cost of $39,000 over a two-year period. The Automatic lubrication system named “SmartLub” regulates lubricant quantity, timing, and application points, ensuring optimal lubrication. The choice of the oil pump was determined by considering both the viscosity of the oil and the head loss within the piping system utilized. By adhering to calculated frequencies, the system extends bearing service life to four years. Furthermore, the manual system reduces labor costs by $400 per roller mill every two years, while unplanned downtimes caused by lubrication issues are minimized. The automatic system eliminates the need for bi-monthly one-day shutdowns in the conventional lubrication systems, saving a total of six days per year. With an estimated lifespan of 20 years, the system achieved a payback period of 1.23 years, demonstrating its cost-effectiveness and long-term benefits. Overall, automation in bearing lubrication enhances machine efficiency, reduces spare parts and maintenance costs, and ensures optimal lubrication in the grain milling sector. Its implementation leads to extended bearing lifespan, reduced downtime, and improved profitability. © 2024, The Author(s), under exclusive license to Springer Nature Switzerland AG.