Testimonials
Pirelli Cable Corporation significantly reduced maintenance costs and downtime using LE's 1250 ALMASOL® High Temperature Lubricant.
key takeaways
Challenge
The customer faced issues with overheating, moisture, and lubricant inefficiency causing excessive wear on the annelear’s primary bearing, necessitating a change every 250 hours to prevent extensive shaft damage.
LE solution
LE’s 1250 ALMASOL® High Temperature Lubricant was suggested to minimize downtime and prolong bearing lifespan.
Results
By using LE’s 1250 ALMASOL High Temperature Lubricant, Pirelli Cable extended bearing replacement intervals from 250 to 375 hours, reducing annual maintenance costs from $6,660 to $4,440, saving $2,220.
There is no question that by using ALMASOL 1250 we have reduced downtime and extended the life of the bearings.
- Roy Stacks, Maintenance
Customer Profile
Pirelli Cable Corporation of Colusa, California manufactures copper and aluminum sheathed cables for underground power systems. Marketing world wide, Pirelli Cable is committed to quality and service and seeks to establish working partnerships with their customers and vendors. They have been an LE customer for over 20 years.
Application
Pirelli Cable uses an S.A.M.P annealer pow ered by a 50 HP drive motor that turns four shafts. The annealer uses high amperage to “soften” the extruded wire as it comes out of the extruder. After the annealing process, the wire is wrapped on spools and then used to make the cables of up to 61 strands.
Challenge
The primary bearing in the annelear w as requiring a change out at 250 hours. Failure to do so can cause bearing failure and very extensive damage to the shaft. High heat and moisture (water-cooling) cause excessive wear conditions on the bearing. Overheating, moisture and “sling-off” were main problems and the recommended lubricant w as not performing w ell. The customer was working to overcome these problems and extend the life of the bearing at the same time.
LE Solution
LE’s 1250 ALMASOL® High Temperature Lubricant was recommended to reduce downtime and extend the life of the bearing.
Results
Previous Maintenance Costs
- Every 2-3 weeks (averages 18 service’s per year)
- Labor: 6 hours (total time) @ $45 per hour = $270
- Bearing: $100 each (total cost)
Prior to introducing LE’s 1250 ALMASOL High Temperature Lubricant to the bearing, the required replacement interval was 250 hours (12 hours per day = 20 days). In a carefully monitored testing program, the bearing was examined and replaced at 275 hours, 300 hours, 345 hours, and 384 hours. Using LE’s 1250 ALMASOL Hi-Temp Lube Pirelli Cable has successfully extended the average change out to 375 hours (12 hours per day = 31 days).
Before 1250: $370 x 18 = $6,660 per year After 1250: $370 x 12 = $4,440 per year
This is an annual savings of $2,220.00 in just this one bearing.