5 years in the making… Secomak & SKF’s development partnership

Secomak and SKF: 5 Years Pioneering the future of Sustainable Bearing Technology

Since the inception of our partnership in 2020, Secomak and SKF have embarked on a transformative journey to innovate and redefine bearing technology. This strategic collaboration has culminated in development of our new hybrid ceramic “Long-Life Bearing Assembly“, setting new industry standards for performance, reliability and maintenance-free operation.

Genesis of the Partnership

In 2020, Secomak, renowned for their advanced industrial solutions, identified a critical need for their equipment line-up: a bearing that could significantly extend operational runtime while eliminating the need for regular maintenance. Recognising SKF’s unparalleled expertise in bearing technology, Secomak sough a collaborative partnership to tackle this ambitious project.

Development Milestones

Research and initial Design

The Journey began with a comprehensive research phase. SKF’s team of engineers and materials scientists collaborated closely

with Secomak’s product development experts to understand the specific demands and operating conditions of Secomak’s applications. This phase involved:

• In-depth Analysis: Evaluating existing bearing performance data and identifying areas of improvement.
• Material selection: Exploring advanced materials, particularly ceramics, known for their high durability, resistance to wear and tear and reduced friction properties.
• Computer Aided Design (CAD): Utilising the latest CAD software to develop and perfect the key design principles.

Prototyping and Testing

 Following the research phase, SKF and Secomak moved into the prototyping stage. This critical phase involved:

• Design
  Iterations: Creating multiple prototypes with varying compositions and configurations to identify optimal design.
• Rigorous Testing: Subjecting the prototypes to extensive laboratory and field tests to evaluate performance under real-world conditions. Key performance indicators included load capacity, rotational speed, temperature stability, and wear resistance. 

Breakthrough Achievements

 Increased Runtime

One of the most significant achievements of the hybrid ceramic bearings is the remarkable increase in operational runtime. Our bearings offer at least a 50% increase, extending the runtime to an extraordinary 30,000 hours and beyond. This milestone is a direct result of:

• Material Superiority: The use of hybrid ceramics, which combine the strength of steel with the resilience of ceramic materials, ensuring superior performance and longevity.
• Innovative Engineering: Advanced design techniques that optimise load distribution and reduce friction, leading to less wear and extended service life.

Maintenance-Free Operation

Another ground-breaking feature of the new bearings is the elimination of lubrication requirements. This innovation translates to:

• Zero Maintenance: Removing the need for regular lubrication checks and replacements, drastically reducing maintenance costs and downtime.
• Enhance Cleanliness: Particularly beneficial in industries such as food and beverage or pharmaceuticals, where contamination from lubricants must be avoided.

Sustainability Benefits

Sustainability is a core value for both Secomak and SKF, and the hybrid ceramic bearings are a testament to this commitment. The bearings offer several significant sustainability benefits:

Reduced Material and Waste

• Elimination of Lubricants: Traditional bearings require regular lubrication, leading to the consumption of significant amounts of grease and oil over their lifespan. The hybrid ceramic bearings eliminate the need for these lubricants, reducing environmental contamination and waste associated with their production, application, and disposal.
• Minimised Waste Generation: With a dramatically extended operational life, the frequency of bearing replacements is reduced, leading to less waste from discarded bearings. This contributes to a reduction in the overall environmental footprint of the equipment.

Decreased Maintenance and Downtime

• Resource Efficiency: Less frequent maintenance means fewer resources are used for bearing replacements and associated activities. This includes reduced use of tools, transportation, and human resources, all contributing to a lower environmental impact.
• Operational Efficiency: By minimising downtime for maintenance, the equipment can operate more continuously and efficiently, leading to higher productivity and better utilisation of resources.

 Increased Efficiency 

• Energy Savings: The Hybrid ceramic bearings are designed to reduce friction significantly. Lower friction means less energy is required to operate machinery, translating to substantial energy saving over time. This reduction not only lowers operational costs but also decreases greenhouse gas emissions associated with energy production.
• Improved performance: Enhanced efficiency and reliability ensures that machinery operates at optimal performance levels, further contributing to energy savings and reducing the overall carbon footprint.

In recognition of the reliability and durability of the newly developed hybrid ceramic bearing assembly, Secomak are confidently offering an extended three-year warranty. This extended warranty underscores:

• Product Confidence: Our rigorous quality control and extensive testing ensure that each bearing meets the highest standards.
• Customer Assurance: Providing Secomak’s customers with added peace of mind and long-term value.

Collaboration and Innovation

The success of this partnership can be attributed to synergy between SKF and Secomak, characterised by:

• Joint Expertise: Leveraging SKF’s deep knowledge in bearing technology and materials science with Secomak’s industry-specific insights and customer requirements.
• Innovative Culture: Both organisations are committed to pushing the boundaries of innovation, fostering a collaborative environment that encourages creative problem-solving and technological advancements.
• Customer-Centric Approach: Continuous engagement with end-users to ensure the final product meets and exceeds their expectations, driving improvements based on real-world feedback.

Future Prospects

While the current achievements are impressive, SKF and Secomak are not resting on their laurels, the potential for further performance enhancements remains substantial. Together our R&D efforts will be focused on:

• Material Advancement: Exploring next generation ceramic materials that could offer even greater durability and performance.
• Design Refinements: Continuous optimisation of bearing design to achieve higher efficiency and reliability.
• Smart Technology Integration: Investigating the incorporation of sensors and IoT capabilities for real-time monitoring and predictive maintenance.
• Higher speed: whilst the initial developments have focused on efficiency and reliability enhancements. The new development paves the way for future performance enhancements with the potential for significant increases in RPM, with bearings running as much as 34% faster.

Industry Recognition

The strength and innovation of the SKF and Secomak partnership have garnered industry attention. We are excited to announce our application for the prestigious Automate Awards for Partnership pf the year. This award recognises the most effective and impactful collaborations within the industry. Winning this award would be a testament to the exceptional results achieved through partnership.

Conclusion

The partnership between Secomak and SKF exemplifies the transformative power of collaboration in driving technological advancements. The development of hybrid ceramic bearings marks a significant lead forward in bearing technology, delivering unparalleled performance and reliability. As we look to the future, SKF remains committed to innovation, confident that our ongoing collaboration with Secomak will continue to set new benchmarks in the industry.

This partnership not only highlights the strength of both organisations but also sets a new standard for excellence in engineering and industrial solutions. Together, Secomak and SKF are pioneering the future of hybrid ceramic bearings, providing unmatched value and performance for our customers.