INCREASE BEARING ENVIROPEELUSA

THERMOPLASTIC

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ANTI- CORROSION

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SYSTEMS

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Enviropeel USA Indianapolis Indiana USA

LIFE BY 500% .
+1 317 631-9111 info@enviropeelusa.com
w w w. e n v i r o p e e l . c o m

In ideal conditions modern bearings will run

continuously for years with very little maintenance.
Yet in some industries, conditions are so far from
ideal that bearings may fail in a few months or
even weeks, requiring frequent replacement and
causing expensive production delays. Conveyor
bearings, for example, are particularly vulnerable,
with constant inundation from dust, debris, slurry
and liquids from the materials that they carry. The
same is true in many other production settings
where these essential components will fail if they
are not given sufcient protection from their
contaminated environment.
Any engineer will tell you that the key to bearing survival is
lubrication; as long as the bearing surfaces are protected from WHY SOME BEARINGS FAIL
wear, they will continue to run cool and vibration free. If
In heavily contaminated environments, large
lubrication fails for any reason, wear increases, bearings quantities of debris and liquids accumulate and
overheat and, sooner or later, the bearing will fail. combine around bearings. Although bearing seals will
In dirty environments, normal maintenance standards may prevent initial ingress, shaft rotation will grind and
not be sufficient to prevent contamination, and trying to keep reduce particles which will eventually pass through
the seals and into the moving parts of the bearing, a
bearing environments clean - by pressure washing, for example
process often made worse by pressure washing. This
- can be problematic. So various shields and caps have evolved reduces lubrication and increases wear causing
to protect bearings, with varying degrees of success. premature failure.
Over the last 15 years Enviropeel has developed a bearing
Dust, debris and slurry accumulate around the
protection system that has consistently produced great results: bearing housing and are rotated through the seal,
along the shaft and into the bearing.
l Preventing contamination ingress
Wear increases as grease
l Preventing corrosion is contaminated with
l Reducing purging abrasive particles.
l Increasing bearing life
The system provides a reliable and cost-effective solution to
premature failure in rotating equipment, prolonging bearing
lifetimes by 500%, dramatically reducing shutdowns and the
need for maintenance. A simple spray application of
Enviropeel will immediately prevent contamination ingress
and stop corrosion in the bearing housing and bolts as well
as reducing the need for purging grease.
Proven Results
Cost savings can be substantial. In Australia, where the
product has been in use for more than 15 years, conveyor
bearings that had required replacement every nine months
were still in perfect condition more than four years after TABLE 1 - PROVEN RESULTS
Enviropeel was used. In the U.S., bearings on a pickling line SAVINGS DATA FROM BHP BILLITON & RIO TINTO
were only lasting six weeks. Eight months after Enviropeel ON STORED BEARINGS

was first applied, the bearings were still fully operational. Rejection for rework without Enviropeel 44.5%

Users regularly experience greater than 500% reduction Rejection rate after Enviropeel 0%

ON OPERATIONAL BEARINGS
in bearing changeouts with enormous savings in
Average bearing life before Enviropeel 9 months*
replacement costs as well as reducing downtime, labor costs Average bearing life using Enviropeel 48+ months
and accident rates. The figures in Table 1 show analysis of Resulting component life increase 500+%

data collected by BHP Billiton and Napier Salt (part of Rio Resulting saving in bearing changeout costs 500+%
Percentage of Enviropeel cost against rebuild cost 5-7%
Tinto Group) who have adopted Enviropeel as standard
Reduction in maintenance costs 95%
practice for all conveyor bearings, both in storage and on
Reduction in risk exposure 90%
production facilities in Australia. *Average bearing life using Enviropeel was calculated from data over four years on
conveyors carrying iron ore and mineral salt in severe conditions
Immediate Savings
TABLE 2 - IMMEDIATE SAVINGS
Table 2 shows figures from a U.S.-based building products
company with heavy cement slurry contamination. At this (A) COST OF BEARING CHANGEOUTS BEFORE ENVIROPEEL

plant, the maintenance program was for eight planned BEARING TYPE No. of Changeouts Cost per Changeout Annual Cost
Tail Pulley Bearings 8 x 2 Bearings $9,000.00 $72,000
bearing changeouts a year to ensure continuous production. 8" Pillowblock
Labor cost per changeout (2 hrs) 8 $150.00 $1,200
With the introduction of Enviropeel, the engineers were able
Estimated production loss (16 hours @ $5000) $80,000
to immediately halve the changeout rate, saving $73,000 for
ANNUAL COST OF CHANGEOUTS $153,200
an investment of only $3,600. Further reductions in the
changeout rate are expected and the company is (B) COST USING ENVIROPEEL WITH 50% REDUCTION IN CHANGEOUT FREQUENCY

incorporating the Enviropeel system into all its U.S. plants. Cost of Enviropeel protection per changeout $900

Cost of bearings + labor per changeout $9,150

Total cost per changeout including Enviropeel $10,050

HOW ENVIROPEEL WORKS Annual changeout cost using Enviropeel (4 x $1050) $40,200

The diagram shows how Enviropeel shields against dirt Estimated production loss (16 x 50% = 8 hours @ $5000) $40,000

and debris while the continuous slow release of built-

ANNUAL COST OF CHANGEOUTS USING ENVIROPEEL $80,200
in inhibiting oils covers all contact surfaces allowing
the shaft to rotate within the coating, preventing TOTAL SAVING USING ENVIROPEEL $73,000
ingress of contaminants - also see project pic on right.

Encapsulation of bearing and shaft prevents Shaft rotates freely within

debris contact with bearing. Enviropeel coating, click pick to
Inhibiting oils coat all link to video.
surfaces lubricating shaft
and preventing corrosion.
 Step 1 Step 2 Step 3 Step 4
Clean up or replace bearing Apply first coat to one half Apply other half of first coat Repeat step 1 and 2 to
as necessary. starting offset from center. with opposite offset. provide second coat.

Application Procedure
The system uses a specially-designed application unit to
apply the Enviropeel material, which is supplied chipped for
easy handling. Using patented heating technology, the units
melt the material into a liquid which can then be sprayed on
to the target substrate. The Enviropeel thermoplastic material
is solid at normal temperatures and, once applied, it cools
rapidly to form a tough, perfectly-fitting second skin that
protects the entire bearing, inside and out. It is manufactured
using a UV-resistant thermoplastic polymer that incorporates
a slow-release inhibiting oil. It is re-usable and recyclable.
The material fully encapsulates but does not bond to the
substrate, so it can also be sprayed directly onto and around
the bearing shaft. The inhibiting oil allows the shaft to rotate
freely within the coating which prevents the build up and entry
of debris and moisture into the bearing, providing unrivalled
protection. The slow-release inhibiting oil prevents corrosion
in the bearing casing and fixing bolts as well as lubricating
Above: Applying Enviropeel.
the rotating shaft.
Below: Before and after
Designed and manufactured in the USA Enviropeel application.
Enviropeel equipment is engineered for reliability and ease of
use. The units are mobile and completely self-contained, with
their own hose, spray gun and compressor. The heating tank
at the top of the unit has a lid for easy entry
of the chipped materials at any time. Using
simple controls and secure safety
systems to monitor material
temperatures and pressure, the
operator is able to adapt flow
rates and spray patterns to suit
any type of substrate and
environmental conditions.

ENVIROPEELUSA
THERMOPLASTIC ANTI- CORROSION SYSTEMS

1128 South West Street, Indianapolis, Indiana, 46225 USA

Phone: 1-317-631-9100 Email: info@enviropeelusa.com