Optimizing Bearing Lubrication with LUBExpert

Introduction

A mining and processing plant operates more than 800 large bearings across its conveyors, crushers and mills. Correct lubrication is critical to reliability.

The problem

Before implementation

• 50% of bearings were greased on a fixed schedule regardless of condition
• 25% were over-greased
• 15% were under-greased
• Average bearing life: 18 months

Consequences

• Premature bearing failures
• Grease over-consumption (+40% above optimal)
• Equipment contamination from excess grease
• High bearing replacement costs

The solution: LUBExpert

What is LUBExpert?

SDT's acoustic bearing lubrication system, which:

• Measures the ultrasonic signal during lubrication
• Shows the optimal point to stop
• Prevents both over- and under-greasing

Rollout

Stage 1: Pilot (3 months)

• One LUBExpert + SDT340 kit
• 50 critical bearings
• Staff training

Stage 2: Rollout (6 months)

• Three kits across all areas
• A database of 800+ bearings
• Integration with the existing CMMS

Stage 3: Optimization

• Setting alarm levels
• Creating work orders
• Continuous improvement

Methodology

The lubrication process with LUBExpert

1. Before measurement

   • Baseline measurement before lubrication
   • Comparison against previous data
   • Assessing whether lubrication is needed

2. During lubrication

   • Real-time ultrasound monitoring
   • Stopping once the optimal level is reached
   • Automatic logging

3. After measurement

   • Verifying the result
   • Trend analysis
   • Updating the database

Results

Bearing life

Period	Average bearing life	Improvement
Before LUBExpert	18 months	—
After 6 months	27 months	+50%
After 12 months	36 months	+100%

Grease consumption

• Before: 120 kg/month
• After: 75 kg/month
• Savings: 45%

Bearing failures

• Before: 8/year
• After: 2/year
• Reduction: 75%

ROI

• Investment: $25,000
• Annual savings: $85,000
• Payback: 3.5 months

Key takeaways

1. Data-driven lubrication

LUBExpert provides objective data for decision-making:

• More than 60% of bearings didn't need lubrication when their scheduled date came around
• Only 25% actually required lubrication

2. Extended bearing life

Correct lubrication doubled service life through:

• Less heat buildup
• Reduced contamination
• Optimal film thickness

3. Reduced costs

Savings came from several fronts:

• Less lubricant consumption
• Fewer bearing replacements
• Reduced labor
• Less downtime

Best practices

Success factors

1. Training — proper technique is essential
2. Database — track all bearings
3. Alarm levels — set appropriate thresholds
4. Trends — monitor changes over time
5. Integration — connect with the CMMS

Lessons learned

• Start with critical bearings
• Standardize the process
• Document everything
• Keep training continuous
• Secure management support

Next steps

1. Extend the program to smaller bearings
2. Roll out automatic lubricators
3. Integrate with vibration monitoring
4. Add remote monitoring capabilities

Testimonial

"LUBExpert revolutionized our approach to lubrication. Now we lubricate based on condition, not calendar. The ROI was phenomenal." — Maintenance Superintendent