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Case Analysis

KALAMINE Mining Custom Spherical Roller Bearings Case | EGEN Bearing OEM

Custom spherical roller bearings fix frequent failure on KALAMINE underground conveyor systems under heavy shock, dust and humidity. Load capacity up 30%, service life doubled.
45days
Custom R&D & sample trial
30%
Load capacity increased
2x
Service life vs imported
18%
Unit purchase cost cut
Failure rate after install

Heavy-duty Underground Mining Conveyor Supplier

KALAMINE MINING is a professional mining operator headquartered in South Africa, supplying ore extraction and conveyor solutions for underground mining projects across the region. With over 20 years of engineering experience, the brand focuses on reliable, long-lifespan conveyor mechanical parts to reduce maintenance cost.

Their conveyor equipment runs all day underground with heavy shock load, putting ultra-high standards on core supporting bearings. Previously relying on imported bearings, KALAMINE aimed to find a localizable supplier with better performance and lower procurement cost.

Reduce Failure Rate & Cut Import Cost

KALAMINE core goal was to eliminate frequent bearing breakdowns on heavy-duty conveyor equipment. The team planned to replace expensive imported bearings with customized domestic bearings featuring stronger loading, self-aligning, dustproof and rust-proof performance, while shortening delivery lead time and lowering unit cost.

Challenges

Heavy-load impact condition

Equipment operates continuously around-the-clock under heavy impact loads. Original bearings had insufficient rollers and limited capacity, causing roller wear and raceway spalling after 5 months.

Shaft misalignment condition

Minor axis offset occurs during operation, requiring strong self-aligning performance and anti-vibration capability.

Harsh underground condition

High humidity and heavy ore dust. Bearings need excellent dustproof, rustproof and long-term lubrication performance.

Customer business objective

Better performance than imported counterparts while cutting procurement cost and delivery lead time.

Solution

Structural Optimization

Redesigned internal structure based on actual load, speed and underground condition; more and larger rollers for higher capacity; custom thick brass cage to disperse impact.

Material & Heat-treatment Enhancement

Carburizing quenching applied to rollers and raceways to improve wear resistance.

Sealing-lubrication System Upgrade

Double-sided thickened sealing with special long-life waterproof grease to resist corrosion from humidity and dust.

Validation & Technical Service

Delivered mechanical simulation reports and completed full-load impact tests before mass production; one-stop maintenance guidance.

Our underground conveyor systems used to break down every 5 months due to worn bearings. EGEN’s customized spherical roller bearings perfectly match our harsh working conditions. Bearing lifespan doubled, procurement cost dropped 18%, and we no longer wait months for imported goods.
KM
Kabelo Mokoena
Maintenance Manager, KALAMINE MINING

Zero Bearing Failure For Long-term Conveyor Operation

The customized spherical roller bearings were installed on KALAMINE underground conveyor units and ran stably for 14 consecutive months without abrasion, overheating or abnormal noise, completely fixing the frequent replacement pain point. KALAMINE gradually suspended imported bearing orders and signed long-term bulk purchase cooperation.

Ready to Upgrade Your Heavy Machinery Bearings?

EGEN Bearing supports full OEM & ODM customization of spherical roller bearings for elevator, mining, metallurgy, and port heavy machinery.
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