In this case study, we explore how a critical bearing failure in an FDA-regulated food-processing application was resolved.
Faced with continuous high-temperature operation, aggressive low-temperature chemical washdowns, and repeated thermal shock, the existing full ceramic bearing cracked and failed in just two weeks, far short of the required three-month service life.
Learn how the right stainless steel with shields bearing solution helped address reliability, performance, and food safety concerns in a demanding operating environment.
Customer
Confidential food processing equipment manufacturer
Industry
Food processing / commercial baking (FDA-regulated)
Applications
High-temperature baking oven conveyor system operating at 500°F, subject to routine chemical bath washdown during sanitation cycles.
Challenge
The application required a bearing capable of surviving continuous high-temperature operation while also withstanding aggressive chemical washdowns at significantly lower temperatures.
The existing full ceramic bearing experienced thermal shock from the rapid temperature change from the washdown, leading to cracking and premature failure. Typical bearing life was approximately 2 weeks. The customer had a required 3-month service life.
Because the operation was FDA-controlled, bearing failure posed a serious food safety risk, as fractured bearing components could potentially enter the food product.
Approach
Failed bearings were returned from the customer to the Boca Bearings engineering department for a comprehensive failure analysis. Engineers evaluated operating temperatures, sanitation procedures, material behavior, and fracture characteristics to identify the failure’s root cause.
Solution
Based on the engineering analysis, Boca Bearings provided the customer with two alternative bearing recommendations specifically designed to mitigate thermal shock while maintaining performance in high-temperature, chemical exposure, and FDA environments. These bearings were produced from stainless steel with shields since long life wasn’t a requirement, and were not sensitive to thermal shock.
Boca Bearings supplied sample bearings and supported the customer through testing and evaluation in the production environment.
Results
Both recommended bearing solutions exceeded the customer’s performance expectations during testing. The selected solution delivered a substantial increase in bearing life, achieving the customer’s target of 3 months of continuous operation without cracking or failure.
Customer Impact
- Significantly improved equipment reliability and uptime
- Reduced the risk of bearing fragmentation in an FDA-regulated food process
- Improved sanitation confidence without compromising bearing life
- Lower maintenance frequency and reduced unplanned downtime
Conclusion
This application demonstrates Boca Bearings’ ability to go beyond component supply and deliver engineering-driven solutions for the most demanding operating environments. Through detailed failure analysis, material expertise, and close collaboration with the customer, Boca Bearings identified the root cause of a critical reliability and food safety issue. They delivered validated solutions that exceeded performance expectations.
By translating complex application challenges into robust, long-life bearing solutions, Boca Bearings continues to help customers improve reliability, protect product integrity, and operate with confidence in extreme and regulated environments.
Bring us your toughest bearing challenge and let our engineers solve it.
For additional assistance, contact one of our bearing experts at Info@bocabearings.com.