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Sealed Roller Bearings

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Upgrading best to betterSKF is the pioneer in roller bearing technology. The company has now upgraded its Explorer roller bearings in terms of load bearing capacity and has also introduced sealed version of the bearings. To know more about the bearing design, its manufacturing process and its application possibilities, ICR visited the SKF India factory at Ahmedabad, Gujarat.

Bearings are precision components, capable of giving millions of smooth revolutions, while absorbing all the wear and tear that the machine will be subjected to without it. A smooth running bearing ensures energy efficient operation. However, a small defect, either in the shaft or in the housing, can lead to misalignment. A misaligned bearing will not run smoothly and will also damage the bearing overtime reducing the machine?s performance. At times, the machine is subject to loads that may cause the misalignment or the equipment just may not be worth enough to be machined with high precision. In such cases self-aligning bearings come to rescue. SKF invented the first self-aligning ball bearing back in 1907. In-fact, all self-aligning bearings have been invented and introduced by SKF. These bearings allow for small deviations in the rotating axis, without affecting the performance of bearing or the machine.

The company introduced spherical roller bearings in 1919, and since then they have been continuously improved. Roller bearings have higher load carrying capacity. They are used in heavy equipments. Rotating cement kilns for example use roller bearings. Roller bearings find applications in grinders, screeners, crushers and such machines where bearings have to perform under tough conditions.

One of the recent developments in self-aligning roller bearings was a new heat treatment process that improves service life. The upgraded Explorer has better service life (almost double) in both contaminated, as well as poorly lubricated conditions. The upgrade increases service life of the bearing boosting the C-value by 15 per cent.

With its designs and material properties perfected, SKF took another leap in the bearing technology. It introduced the worlds first sealed roller bearing. Sealed roller bearings ensure that the contaminants stay out of the bearing lubricant, thus extending the bearing life almost four fold. It also eliminates the need for maintenance shutdowns for replacing bearing lubrication. As a result, there is no used grease to be treated, saving oil and grease treatment cost to the company, while being environment friendly.

For example, pinion gear drives at a mining plant required frequent relubrication. The company had its 100 bearings relubricated with 10 tonnes of grease per year, and the drives still failed prematurely. The dust and contamination was too high to handle for the bearings. Finally, the company switched to sealed bearings, which lasted twice as long, and the grease consumption was reduced by more than 95 per cent.

Self-aligning sealed bearings have definite application in material handling equipment that have to perform under dust laden environment. The company offers about 104 types of sealed bearings as of today.

Seal the performance
Henrik Wickberg, Project Manager, Spherical Roller Bearings (SRB), SKF Henrik Wickberg, in an interaction with ICR elaborates on the factors that influence bearing performance and how the seal extends bearing life even in harsh conditions.

How does the housing impact bearing performance?
Bearing performance depends on both internal and external factors. Internal factors are the roundness of bearing, the surface roughness of bearing components and the interaction between internal geometries. External factors include the roundness of the shaft and the housing in which the bearing is fixed. These factors will influence bearing performance.

Even if the bearing is round and perfect, if you put it in a housing that is not, the bearing will deflect and will lead to uneven load distribution. That will lower bearing performance. So I recommend using high quality housing to get the best from your bearing.

How do you compare a sealed bearing with an open bearing in the same genre for similar application?
SKF has always been looking for ways to further improve bearing performance. One way is to look at new designs and exploring new materials. The other way is to protect the bearing, which also improves the performance. One such way is the use of seal for bearing protection.

While a quarter of our bearings operate in good conditions, such as proper lubricant, free of contaminants, etc., the remaining bearings are used in harsh to very harsh environments. Use of seal protects the bearing from contaminants and allows the bearing to perform, as it should even in such conditions.

As the bearing is lubricated at the factory itself, the quality is assured, and in most cases it is lubricated for life. Sealed bearings have rating life 2-4 times more than open bearings.

What is C value, and the a SKF factor?
C value helps in projecting the bearing life. It is determined as per the ISO standards and is a function of the number of rollers or balls in a bearing, function of effective length of roller that will bear the load, diameter of the roller, angle of race way, etc. The calculation looks at the life of bearing for one million revolutions.

C value is very important for engineers as it helps in judging the performance of a bearing. However, different manufacturers present the C value in different ways. For example, while working out the C value you have to factor the lubrication in the calculation, which is given as the Kappa value. Now some manufacturers use Kappa value as 4. It is the highest value representing absolutely clean lubricant and no friction at all. That will give you a very high C value. Now that is not exactly against the rule book, but it might confuse the buyer. Not many people have the catalogue or read the catalogue that carefully. One must understand that if you factor poor lubrication or contaminants, the bearing performance drops drastically. So calculating high C value based on high kappa value is incorrect.

We use Kappa value of ?1? to match the conditions in reality as much as possible, while some use Kappa 2. We also give performance as per the aSKF factor, which is more accurate in stating the bearing performance. The aSKF factor is peer reviewed by experts to be a better way of indicating bearing life and performance.

How do you detect bearing issues? And can bearings be refurbished?
There are a few indicators of bearing failure. Temperature is the most commonly observed parameter. High temperature indicates friction in the bearing. Another factor is vibration, which could be due to defective shaft, housing, or misalignment between these components. It could also be due to uneven load distribution. Worn out bearings at the end of life do vibrate, otherwise it could be due to a defective bearing itself.

Worn out bearings could be refurbished, depending on the extent of damage. At times the surface could be refurbished or the rollers could be replaced. It is more profitable to refurbish large bearings rather than small ones, depending on the application. We have a solutions factory where we refurbish bearings and re-certify that bearing for its extended life.

Positioning it right
Dinesh Mirjurkar, General Manager, Marketing and Business Excellence, Regional Sales and Services, SKF India

SKF has a strong market reputation. Clients by default have high expectations not just from the products but also from after-sales service. The company ensures that the customers are satisfied at every stage and that the products are positioned suitably. Dinesh Mirjurkar talks more about this with ICR.

Where do these large size bearings find applications?
These bearings have applications in the mining and mineral processing industries, in paper pulp processing, steel and cement manufacturing plants, coal crushing machines, etc.

Who are your leading customers in cement industry?
We are supplying bearings to FLSmidth, Loesche, etc. The bearings have multiple application areas and are consumed through a network of distributors.

They are used in cement manufacturing equipment such as vertical grinding mill, cement mill, crushers, screeners, etc.

How do sealed and open bearings compare cost wise?
Sealed SRB is only slightly costlier than the open bearing. So the cost advantage is very high when compared to open bearings. Besides, you are avoiding system shut down to replace the bearing or to do any bearing maintenance job. The bearing does not require re-lubrication and so there is no cost associated with the disposal of used grease from the bearings. That too is a saving. We have positioned it where, though it is a bit costlier than open bearing, it encourages our customers to try the new variant.

How are you tackling counterfeiting issues?
We are dealing with it at various levels. We are educating our customers about what to look for when they source bearings. We have improved the packaging, making it difficult to copy for fake part manufacturers and makes it easier for buyers to spot the difference.We are also fighting it at legal levels, taking legal measures to ensure that counterfeiting is discouraged.

Delivering with perfection
Ajay Naik, Factory Manager, SKF Ahmedabad
SKF has technologically advanced manufacturing facilities across the globe that conform to uniform standards all over. Ajay Naik talks with pride about the SKF India plant. Excerpts.

Tell us a bit about your plant.
The SKF factory at Ahmedabad was inaugurated in 2009. Currently, the factory is spread over around 26,700 sq.m, and has an additional 20,400 sq.m of land for further expansion. The facility is ISO 14001 certified and has won the coveted LEED (Leadership in Energy and Environmental Design) Gold certification conferred by IGBC (India Green Building Council). The Ahmedabad factory is the first bearing factory in India to be certified by LEED rating and the third SKF facility, amongst all 140 plus plants across the globe to get the LEED Gold certification.

Medium to large scale bearings are manufactured at this plant.The facility for heat treatment is unlike you will see at other plants. It is a completely automated facility with state-of-the-art technology. Operators can man the furnace from their cabins and monitor each activity closely. The plant has facilities for black oxidation and phospating.

How many units are manufactured by SKF every month?
It depends on the size and the kind of bearing that we are manufacturing at a given point. As a ballpark figure, we are manufacturing around 4000-5000 units a month.

How do you maintain uniform standards across all plants in several countries?
Everything right from approval of steel to the testing of the final product is centrally driven. All plants of SKF across the globe are allowed to purchase steel only from the centrally approved steel supplier. The vendor qualification is a rigorous process and takes around 9 to 18 months. This is to ensure that the raw material quality, the metallurgical characteristics are uniform and as per the set standards across all SKF plants.The final product too is tested and approved at the central facility. Hence, there are absolutely no variations in product.

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Price hikes, drop in input costs help cement industry to post positive margins: Care Ratings

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Region-wise,the southern region comprises 35% of the total cement capacity, followed by thenorthern, eastern, western and central region comprising 20%, 18%, 14% and 13%of the capacity, respectively.

The cement industry is expected to post positive margins on decent price hikes over the months, falling raw material prices and marked drop in overall production costs, said an analysis of Care Ratings.

Wholesale and retail prices of cement have increased 11.9% and 12.4%, respectively, in the current financial year. As whole prices have remained elevated in most of the markets in the months of FY20, against the corresponding period of the previous year.

Similarly, electricity and fuel cost have declined 11.9% during 9M FY20 due to drop in crude oil prices. Logistics costs, the biggest cost for cement industry, has also dropped 7.7% (selling and distribution) as the Railways extended the benefit of exemption from busy season surcharge. Moreover, the cost of raw materials, too, declined 5.1% given the price of limestone had fallen 11.3% in the same aforementioned period, the analysis said.

According to Care Ratings, though the overall sales revenue has increased only 1.3%, against 16% growth in the year-ago period, the overall expenditure has declined 3.2% which has benefited the industry largely given the moderation in sales.

Even though FY20 has been subdued in terms of production and demand, the fall in cost of production has still supported the cement industry by clocking in positive margins, the rating agency said.

Cement demand is closely linked to the overall economic growth, particularly the housing and infrastructure sector. The cement sector will be seeing a sharp growth in volumes mainly due to increasing demand from affordable housing and other government infrastructure projects like roads, metros, airports, irrigation.

The government’s newly introduced National Infrastructure Pipeline (NIP), with its target of becoming a $5-trillion economy by 2025, is a detailed road map focused on economic revival through infrastructure development.

The NIP covers a gamut of sectors; rural and urban infrastructure and entails investments of Rs.102 lakh crore to be undertaken by the central government, state governments and the private sector. Of the total projects of the NIP, 42% are under implementation while 19% are under development, 31% are at the conceptual stage and 8% are yet to be classified.

The sectors that will be of focus will be roads, railways, power (renewable and conventional), irrigation and urban infrastructure. These sectors together account for 79% of the proposed investments in six years to 2025. Given the government’s thrust on infrastructure creation, it is likely to benefit the cement industry going forward.

Similarly, the Pradhan Mantri Awaas Yojana, aimed at providing affordable housing, will be a strong driver to lift cement demand. Prices have started correcting Q4 FY20 onwards due to revival in demand of the commodity, the agency said in its analysis.

Industry’s sales revenue has grown at a CAGR of 7.3% during FY15-19 but has grown only 1.3% in the current financial year. Tepid demand throughout the country in the first half of the year has led to the contraction of sales revenue. Fall in the total expenditure of cement firms had aided in improving the operating profit and net profit margins of the industry (OPM was 15.2 during 9M FY19 and NPM was 3.1 during 9M FY19). Interest coverage ratio, too, has improved on an overall basis (ICR was 3.3 during 9M FY19).

According to Cement Manufacturers Association, India accounts for over 8% of the overall global installed capacity. Region-wise, the southern region comprises 35% of the total cement capacity, followed by the northern, eastern, western and central region comprising 20%, 18%, 14% and 13% of the capacity, respectively.

Installed capacity of domestic cement makers has increased at a CAGR of 4.9% during FY16-20. Manufacturers have been able to maintain a capacity utilisation rate above 65% in the past quinquennium. In the current financial year due to the prolonged rains in many parts of the country, the capacity utilisation rate has fallen from 70% during FY19 to 66% currently (YTD).

Source:moneycontrol.com

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Wonder Cement shows journey of cement with new campaign

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The campaign also marks Wonder Cement being the first ever cement brand to enter the world of IGTV…

ETBrandEquity

Cement manufacturing company Wonder Cement, has announced the launch of a digital campaign ‘Har Raah Mein Wonder Hai’. The campaign has been designed specifically to run on platforms such as Instagram, Facebook and YouTube.

#HarRaahMeinWonderHai is a one-minute video, designed and conceptualised by its digital media partner Triature Digital Marketing and Technologies Pvt Ltd. The entire journey of the cement brand from leaving the factory, going through various weather conditions and witnessing the beauty of nature and wonders through the way until it reaches the destination i.e., to the consumer is very intriguing and the brand has tried to showcase the same with the film.

Sanjay Joshi, executive director, Wonder Cement, said, "Cement as a product poses a unique marketing challenge. Most consumers will build their homes once and therefore buy cement once in a lifetime. It is critical for a cement company to connect with their consumers emotionally. As a part of our communication strategy, it is our endeavor to reach out to a large audience of this country through digital. Wonder Cement always a pioneer in digital, with the launch of our IGTV campaign #HarRahMeinWonderHai, is the first brand in the cement category to venture into this space. Through this campaign, we have captured the emotional journey of a cement bag through its own perspective and depicted what it takes to lay the foundation of one’s dreams and turn them into reality."

The story begins with a family performing the bhoomi poojan of their new plot. It is the place where they are investing their life-long earnings; and planning to build a dream house for the family and children. The family believes in the tradition of having a ‘perfect shuruaat’ (perfect beginning) for their future dream house. The video later highlights the process of construction and in sequence it is emphasising the value of ‘Perfect Shuruaat’ through the eyes of a cement bag.

Tarun Singh Chauhan, management advisor and brand consultant, Wonder Cement, said, "Our objective with this campaign was to show that the cement produced at the Wonder Cement plant speaks for itself, its quality, trust and most of all perfection. The only way this was possible was to take the perspective of a cement bag and showing its journey of perfection from beginning till the end."

According to the company, the campaign also marks Wonder Cement being the first ever cement brand to enter the world of IGTV. No other brand in this category has created content specific to the platform.

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In spite of company’s optimism, demand weakness in cement is seen in the 4% y-o-y drop in sales volume. (Reuters)

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Cost cuts and better realizations save? the ?day ?for ?UltraTech Cement, Updated: 27 Jan 2020, Vatsala Kamat from Live Mint

Lower cost of energy and logistics helped Ebitda per tonne rise by about 29% in Q3
Premiumization of acquired brands, synergistic?operations hold promise for future profit growth Topics

UltraTech Cement
India’s largest cement producer UltraTech Cement Ltd turned out a bittersweet show in the December quarter. A sharp drop in fuel costs and higher realizations helped drive profit growth. But the inherent demand weakness was evident in the sales volumes drop during the quarter.

Better realizations during the December quarter, in spite of the 4% year-on-year volume decline, minimized the pain. Net stand-alone revenue fell by 2.6% to ?9,981.8 crore.

But as pointed out earlier, lower costs on most fronts helped profitability. The chart alongside shows the sharp drop in energy costs led by lower petcoke prices, lower fuel consumption and higher use of green power. Logistics costs, too, fell due to lower railway freight charges and synergies from the acquired assets. These savings helped offset the increase in raw material costs.

The upshot: Q3 Ebitda (earnings before interest, tax, depreciation and amortization) of about ?990 per tonne was 29% higher from a year ago. The jump in profit on a per tonne basis was more or less along expected lines, given the increase in realizations. "Besides, the reduction in net debt by about ?2,000 crore is a key positive," said Binod Modi, analyst at Reliance Securities Ltd.

Graphic by Santosh Sharma/Mint
What also impressed analysts is the nimble-footed integration of the recently merged cement assets of Nathdwara and Century, which was a concern on the Street.

Kunal Shah, analyst (institutional equities) at Yes Securities (India) Ltd, said: "The company has proved its ability of asset integration. Century’s cement assets were ramped up to 79% capacity utilization in December, even as they operated Nathdwara generating an Ebitda of ?1,500 per tonne."

Looks like the demand weakness mirrored in weak sales during the quarter was masked by the deft integration and synergies derived from these acquired assets. This drove UltraTech’s stock up by 2.6% to ?4,643 after the Q3 results were declared on Friday.

Brand transition from Century to UltraTech, which is 55% complete, is likely to touch 80% by September 2020. A report by Jefferies India Pvt. Ltd highlights that the Ebitda per tonne for premium brands is about ?5-10 higher per bag than the average (A cement bag weighs 50kg). Of course, with competition increasing in the arena, it remains to be seen how brand premiumization in the cement industry will pan out. UltraTech Cement scores well among peers here.

However, there are road bumps ahead for the cement sector and for UltraTech. Falling gross domestic product growth, fiscal slippages and lower budgetary allocation to infrastructure sector are making industry houses jittery on growth. Although UltraTech’s management is confident that cement demand is looking up, sustainability and pricing power remains a worry for the near term.

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