Customer Overview
A major UK aggregates processing facility operating multiple continuous conveyor systems for crushed stone transport. The site relies on uninterrupted conveyor operation to maintain production throughput, with downtime carrying significant financial consequences.
The Challenge
The customer was experiencing repeated bearing failures on a critical conveyor drive pulley supporting a large diameter shaft. The conveyor operated continuously in a harsh environment, exposed to dust, vibration and heavy radial loads.
Replacing the existing solid spherical roller bearing presented significant operational challenges:
- Complete removal of drive coupling and gearbox required for every bearing change
- Heavy lifting equipment and crane hire needed on each occasion
- Conveyor downtime of 2–3 days per bearing replacement
- Lost production estimated at £25,000–£40,000 per day
- Increased safety risks during disassembly and reassembly
The customer needed a solution that would reduce downtime during maintenance, improve bearing reliability in harsh aggregates conditions, eliminate the need for major disassembly, and lower total cost of ownership.
Orbic's Solution
Orbic Engineering Solutions recommended and supplied Timken® Split Cylindrical Roller Bearings — designed specifically for heavy industrial and trapped applications such as conveyor systems.
Unlike conventional bearings, Timken split bearings are engineered in two halves, allowing installation directly onto the shaft without removing adjacent components.
Key Product Features
- Fully split inner and outer races for installation without shaft disassembly
- Heavy-duty cylindrical roller design engineered for high radial loads
- Sealing options suitable for aggressive aggregates environments
- Precision engineered brass cages for strength and reduced friction
Installation was completed during a scheduled maintenance window without removal of the drive assembly.
Results
Improved Reliability & Service Life
Timken split bearings provided improved load handling capacity, increased resistance to contamination and longer operational lifespan in the demanding aggregates environment.
Improved Maintenance Safety
Maintenance teams were able to replace the bearing without dismantling the drive system, significantly reducing manual handling risks and simplifying the maintenance procedure.
"The Timken split bearing solution has transformed our conveyor maintenance. What previously took days can now be completed in hours, with minimal disruption to production."
— Maintenance Manager, UK Aggregates Processing FacilityIdeal Applications for Timken Split Bearings
- Quarry and aggregate transfer conveyors
- Cement plants and bulk material handling systems
- Mining conveyors and heavy industrial equipment
- Any trapped shaft application where disassembly is costly or impractical
Orbic Engineering Support
Orbic supplied the complete bearing solution as an authorised Timken distributor, including application assessment, bearing selection, supply and technical support — ensuring the customer received a fully engineered and reliable solution.