Bearing Refurbishment: Extending Product Life Cycle & Embracing a Circular Economy

The Paris Agreement has called for emissions to be reduced by 45% by 2030 and to achieve net zero by 2050. This global initiative has prompted industries worldwide to actively seek sustainable practices.

In this endeavor, Schaeffler India has taken the lead by establishing a facility for bearing refurbishment in Jamshedpur, Jharkhand to cater to the refurbishment needs of various customers in India. This facility in the Asia Pacific region is set up in partnership with Premier (India) Bearings Ltd., an authorized Industrial distributor. This facility is in close proximity to the major integrated steel plants and other heavy industry customers in the region. 

Refurbishment of bearing not only helps to extend the product life cycle but also results in significant cost savings by aligning with the principles of the circular economy – a concept that promotes a shift from the traditional linear model to a more sustainable and environmentally friendly approach.

Extending Product Life Cycle for Cost Savings

Bearings play a pivotal role in industrial machinery, ensuring smooth and efficient operations. However, like all mechanical components, bearings experience wear and tear over time. In the past, the conventional approach to dealing with worn bearings was to replace them with new ones, resulting in both financial and environmental costs. Bearing refurbishment, however, offers an alternative that can dramatically extend the lifespan of bearings.

By refurbishing bearings instead of replacing them, industries can realize substantial cost savings. The process involves disassembling, cleaning, inspecting, repairing, and reassembling the bearings to restore them to their optimal functionality. This not only reduces the need for frequent replacements but also significantly reduces the associated procurement and disposal costs.

Embracing the Circular Economy

Bearing refurbishment is in line with the principles of the circular economy – a concept that challenges the traditional linear model of "take, make, dispose" and promotes a more sustainable approach where resources are kept in use for as long as possible. 

Refurbishing bearings exemplify this circularity by reintroducing worn components back into the production cycle, thus minimizing waste and reducing the consumption of raw materials.

Other key benefits of bearing refurbishment include:
•    Reduced life cycle costs 
•    Increased operating life
•    Savings in material and energy costs
•    Reduced inventory costs
•    High flexibility through short lead times
•    Feedback on the characteristics and frequencies of damage

Schaeffler, a global leader in rolling bearing and industrial automation solutions, found that a Level-2 Refurbishment of a medium size 2-Row Tapered Roller Bearing resulted in savings of 49 tons of CO2 equivalent to:

199,015km by plane

294,000km by car

1,139,736km by train

Waste Reduction and Environmental Conservation

A significant advantage of bearing refurbishment is the direct reduction of waste. Traditional disposal of worn-out bearings can contribute to the growing problem of accumulation of solid metal waste and related lubricants associated with it, which poses serious environmental and health risks. By choosing to refurbish bearings, companies in India can actively contribute to waste reduction and contribute to a cleaner and healthier environment.

The refurbishment process involves inspection and remanufacturing using techniques and technologies that help restore the bearing to as-new condition. This helps the companies to derive an extended life for the refurbished bearings at a very nominal cost, thereby, resulting in savings and aligning with broader sustainability goals.

Shortened Lead Time and Inventory Cost Reduction

In addition to its environmental and financial benefits, bearing refurbishment also offers a strategic advantage when it comes to lead time and inventory management. Traditional procurement of new bearings are often associated with longer lead times, potentially causing disruptions in production schedules. Refurbishment, on the other hand, can significantly shorten lead times, ensuring that industries can quickly get their machinery back up and running.

Additionally, refurbishment supports a reduction in customers' inventory costs. Instead of maintaining large stocks of new bearings, businesses can rely on a more responsive refurbishment process to supply their needs. This just-in-time approach not only streamlines operations but also frees up valuable resources that can be invested elsewhere in the business.

Demonstrating the Transformative Power of Bearing Refurbishments Across Diverse Industrial Sectors

Bearing refurbishments have demonstrated their remarkable benefits across various industrial sectors, as exemplified by these four diverse case studies from India.

Refurbishment of Spherical Roller Bearings - for a Continuous Caster application in one of the largest Steel manufacturers in India

The refurbishment of these Spherical Roller Bearings (bearing no.: 24030-E1, 23024 E1, 23026-E1) ranging in size from OD 120mm to 150mm, used in caster segment rolls, resulted in 100% extended bearing life cycle and 70% cost savings. 

Refurbishment of Four-row Cylindrical Roller Bearing in Wire & Rod Mill in the Steel sector

Similarly, the refurbishment of this Four-Row Cylindrical Roller Bearing (bearing no.: 507335/E18, 507333/334B, 507335/F013.H) sized between 400 to 450mm achieved 80% extended bearing life cycle and 70% cost savings, all of which are crucial for Wire & Rod Mill (WRM) operations of the steel sector in India. 

Refurbishment of Spherical Thrust Roller Bearing for one of the largest Steel Forged Component Manufacturer in India

The Thrust Spherical Roller Bearings (bearing no.: 292/1060-E1-MB) with an impressive OD of 1400mm, employed in the flywheel of a hydraulic press, were refurbished to maintain precision and reliability, ensuring product quality, and preventing costly maintenance fees in the event of machine failure. This refurbishment extended the bearing life cycle by an expected 80% and achieved 65% cost savings.

Refurbishment of Spherical Roller Bearing for Vertical Roller Mill in Cement sector

This customer within the cement sub-sector experienced enhanced efficiency through the refurbishment of Spherical Thrust Roller Bearing (bearing no.: 231/670-B-MB) with an OD of 1090mm, utilized in an Indian coal mill. This refurbishment extended the bearing life cycle by an expected 80% and achieved 60% cost savings.

These four Indian case studies had a collective reduction in CO₂emissions of 25 tonnes, underscoring how bearing refurbishments stands as a prime example of how industries can align their operational practices with sustainability goals. 

By extending the product life cycle, contributing to the circular economy, reducing waste, and supporting more efficient inventory management, India's refurbishment service offers a win-win situation for both businesses and the environment. As industries continue to explore ways to optimize their operations, bearing refurbishment emerges as a beacon of responsible and forward-thinking practices.

Find out more about our bearing refurbishment services and how India's success story can inspire global sustainability efforts.

Story Owner:
Hirak Biswas
AGM – Distribution Sales

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