Minimising Bearing Downtime: A Practical Guide for Manufacturing Engineers
Minimising bearing downtime in manufacturing environments is mission critical. Because, every unplanned stop costs time, money, and trust and when the culprit is a failed bearing, the frustration is doubled — it’s often avoidable.
Minimising bearing downtime isn’t about guesswork or crossing your fingers after installation. It’s about understanding how your environment, specification, and maintenance all affect service life.
This guide tackles the real-world causes of downtime and shows how to prevent bearing failure before it ever reaches the shop floor.
What causes unexpected bearing downtime in manufacturing?
Bearings fail for three main reasons: mechanical, environmental, and human.
- Mechanical: Misalignment, excessive load, or exceeding speed ratings.
- Environmental: Dust, moisture, chemical exposure, or extreme temperature swings.
- Human: Poor installation, missed lubrication, or using generic “will do” components.
The common thread? Every cause is preventable with the right spec and good practices.
The right bearing specification will stop the failure; minimising bearing downtime
A bearing can “fit” but still be completely wrong for the job.
- Match load and speed ratings: Under-spec and it fails fast; over-spec and you waste money and space.
- Pick the right materials: Chrome steel for dry, clean zones; stainless or polymers for corrosive, wet, or chemical-heavy areas.
- Seal smart: Labyrinth seals for dusty sites; IP66/IP69K for wet or washdown zones.
Correct specification is the cheapest insurance you’ll ever buy.
What are the warning signs a bearing is about to fail?
Spotting trouble early can save hours of downtime. Look for:
- Vibration changes: A sudden buzz, hum, or “wobble” under normal load.
- Temperature spikes: Localised heat on the housing or shaft.
- Lubricant issues: Grease leakage, discolouration, or a milky appearance after washdowns.
Pro tip: Keep a failure log by location. Repeat failures are almost always a spec or installation issue.
Does lubrication play a role in minimising bearing downtime?
Lubrication is often treated as an afterthought — until it isn’t.
- Grease viscosity: Match to speed and load. High speeds need lighter grease to reduce drag.
- Automatic systems: Perma units keep bearings lubricated even on weekends and night shifts.
- Avoid over/under-greasing: Too little dries out the bearing; too much blows seals and wastes product.
How can installation practices extend bearing life?
Even the perfect bearing fails if it’s badly installed.
- Check shaft alignment: Misalignment causes uneven wear.
- Mount for drainage: Sloped mounts stop water pooling under housings.
- Torque correctly: Avoid hammer fitting; use pullers or presses where needed.
The best installations happen with clean, prepped surfaces and the right tools — not shortcuts.
Can maintenance schedules really reduce unplanned stops?
Yes — but only if they’re realistic and followed.
- Predictive maintenance: Uses vibration or thermal monitoring to detect changes before failure.
- Preventive maintenance: Calendar-based checks to catch wear and lubrication issues.
- Documentation: Keep records for audits and to track recurring trouble spots.
How do bearings perform in wet-process cleanrooms?
Wet cleanrooms — common in food, beverage, dairy, and biotech production — push bearings to their limits.
Common causes of downtime:
- Seal failure from repeated washdowns: Water and chemicals breach seals, washing out grease.
- Corrosion of housings or inserts: Standard steels pit and flake under constant moisture.
- Bacterial contamination: Poor drainage lets water sit, creating hygiene risks.
Solutions:
- Use IP66/IP69K seals: Stops ingress from high-pressure jets.
- Fit stainless or polymer housings: Corrosion-proof and chemical-resistant.
- Specify NSF H1 grease: Safe for incidental product contact.
- Choose self-draining housings: Prevents water pooling around the bearing.
How do bearings perform in dry-process cleanrooms?
Dry cleanrooms — such as in electronics, aerospace, or pharmaceutical manufacturing — have their own failure patterns.
Common causes of downtime:
- Particle shedding: Poor material choice creates airborne contamination.
- Seal drag at high speed: Overly tight seals create friction and heat.
- Lubricant outgassing: Standard greases can release vapours, contaminating sensitive products.
Solutions:
- Use ceramic or hybrid bearings: Low particle emission and no rust risk.
- Fit non-contact seals: Reduce drag while keeping contaminants out.
- Select low-outgassing lubricants: Designed for cleanroom air purity standards.
What’s the quickest way to minimise bearing downtime?
When the same location fails repeatedly, you’re looking at a deeper issue than bad luck.
- Check the environment: Dust, washdowns, or high heat?
- Review the spec: Does it match the load, speed, and conditions?
- Inspect installation: Is alignment off or drainage poor?
Replace only when you know why it failed. Otherwise, you’re just restarting the clock on the next stoppage.
Conclusion: keep your plant moving by minimising bearing downtime
Minimising bearing downtime isn’t complicated. It’s about:
- Specifying the right bearing for the job.
- Installing it correctly.
- Maintaining it on a realistic schedule.
Do these three things consistently and you’ll prevent bearing failure before it starts — saving time, money, and a lot of weekend callouts.
TOM HAMLETT
Tom Hamlett is a respected authority in the global bearings marketplace, with over 35 years of experience in industrial bearings, lubricants, and adhesives across a wide range of industries. As Managing Director of Godiva Bearings, Tom has built a trusted business renowned for its commitment to quality, technical expertise, and ethical service. Under his leadership, Godiva Bearings has remained the UK’s only trade-exclusive bearings supplier, proudly serving engineers and distributors worldwide since 1977. Tom’s in-depth knowledge and dedication have cemented his reputation as one of the most knowledgeable figures in the sector.