TFL bearings help paper manufacturer save $110,000 annually
Paper Machine Dryer Section
A leading manufacturer in the paper sector. The dryer section of their primary paper machine is the most critical asset determining both production capacity and final product quality.
This massive assembly of steam-heated dryer cylinders, weighing hundreds of tons, functions as the heart of the production line. Operating at temperatures exceeding 120°C (250°F), it continuously and stably evaporates moisture from the paper web, pressing it into finished paper of a specific dryness and strength. Any unplanned downtime of a dryer cylinder bearing halts the entire production line.
Key Facts
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Root Cause 1: High-Temperature Bearing Creep
- Mechanism of Failure: High-temperature steam continuously heats the dryer cylinders, with heat transferring to the journals and bearing inner rings. Due to a slight difference in the thermal expansion coefficients between the steel journal and the bearing steel, microscopic slippage occurs between the inner ring and its shaft seat. This "creep" phenomenon acts like sandpaper, slowly but relentlessly wearing down the journal and enlarging the fitting clearance.
- Resulting Impact: The loose fit led to severe vibrations, compromising paper uniformity and causing irreversible damage to the costly dryer cylinder journals, forcing the customer to undertake expensive weld repairs or complete shaft replacement.
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Root Cause 2: Misalignment from Thermal Expansion
- Mechanism of Failure: Over its length of several dozen meters, the paper machine frame experiences minute expansion and contraction during heat-up and cool-down cycles. This creates dynamic and unpredictable angular misalignments between the bearing housings at opposite ends of the dryer cylinders.
- Resulting Impact: Conventional bearings could not adequately compensate for this misalignment, inducing internal stresses and uneven load distribution on the rollers. This drastically reduced the bearing's fatigue life to well below its theoretical potential, often requiring replacement in under 12 months and leaving the maintenance team in a constant state of reaction.
The TFL Solution
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Anti-Creep Coating on the Inner Ring Bore:
Practical Description: We applied a proven phosphate coating to the bearing's inner ring bore. This micro-rough, wear-resistant layer significantly increases the static friction between the inner ring and the journal, effectively "locking" the fit and preventing the micro-slippage that causes creep.
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Enhanced Dimensional Stabilization (S2 Class):
Practical Description: The bearing rings and rollers underwent a special high-temperature tempering process. This mature heat treatment ensures the bearing's material structure and geometry remain highly stable at operating temperatures up to 200°C (392°F), preventing dimensional changes and maintaining the correct internal clearance.
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Optimized Lubrication & Sealing Synergy:
Practical Description: We recommended the customer switch to a TFL-approved synthetic circulating oil with superior anti-emulsification properties and high-temperature stability. In parallel, we advised upgrading the housing seals to a high-temperature fluoroelastomer (FKM) lip seal, whose enhanced elasticity and aging resistance provide a more robust barrier against moisture ingress.
Product Features
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Handles Misalignment: The core self-aligning capability effortlessly accommodates thermal expansion-induced shaft deflection.
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Creep-Resistant: The phosphated inner ring bore firmly grips the journal, eliminating wear.
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High-Temp Stability: The S2 heat treatment ensures no deformation at temperatures up to 200°C.
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High Load Capacity: Optimized internal geometry easily supports the heavy static and dynamic loads of the dryer cylinder.
Application effects
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Before: Bearings showed excessive vibration after an average of 10 months and required replacement within a year. The plant suffered at least one costly, unplanned shutdown annually, constantly disrupting production schedules and stressing the maintenance team.
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Now: The anti-creep coating eliminated the root cause of journal wear. The S2 heat stabilization ensured reliable performance at high temperatures. The bearing service life has been extended from less than 12 months to over 24 months, perfectly aligning with the plant's major overhaul schedule and achieving "set-it-and-forget-it" operation. The maintenance team's focus has shifted from "firefighting" to preventative maintenance.
Cost-Savings Breakdown
| LOWER SPARE PARTS COSTS | $8,500 |
| ELIMINATED DOWNTIME LOSSES | $96,000 |
| REDUCED PRODUCT SCRAP | $5,500 |
| ANNUALIZED COST SAVINGS | $11,000 |
About TFL BEARINGS
Why is TFL BEARINGS frequently chosen as the specified bearing brand bymajor international companies?
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