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Home » Whitepaper » Driving Efficiency in Your Bearing Spend KG International Understanding the sources of bearing procurement inefficiency In the rigorous landscape of industrial operations, efficiency and longevity of heavy machinery are nonnegotiable. Critical components such as bearings and lubrication are the linchpins in maintaining optimal operational continuity and preventing costly downtimes. However, procurement inefficiencies often lead to unnecessary expenditure and diminished machinery life. Contamination from the relentless operative environment significantly accelerates wear and tear, jeopardizing both productivity and the longevity of equipment and machinery. Proactively addressing procurement and maintenance challenges like below are essential for safeguarding equipment functionality: a. Incorrect bearing selection and technological ignorance Bearing selection might seem like a mundane task, but it’s far from it. Choosing the appropriate bearing is crucial for maintaining seamless production. Factors such as load capacity, speed, temperature, and environmental conditions are critical to avoid accelerated wear, premature failure, and costly production stoppages. b. Insufficient focus on proper training and maintenance Lack of proper training on bearing maintenance can significantly impact bearings’ life, resulting in premature bearing failure. Mostly such failures are attributed to one or more of the following causes: Mishandling in storage and transportation Incorrect selection of shaft and housing fits Lack of mounting practice and missing layouts Insufficient knowledge about the application Defective bearing seats in shafts and housings Defective bearing seats in shafts and housings c. Overspending due to misconceptions about the superiority of European/Japanese bearings This assumption has led to overspending in procurement. Technological advancements, material science, and globalization have minimized quality disparities among global manufacturers. Emerging companies like KG International offer high-quality bearings at competitive prices. Today, a bearing’s origin is less reflective of its quality due to enhanced manufacturing and quality control standards. d. Focusing excessively on price while neglecting quality Prioritizing lower cost over quality in bearing selection can lead to premature wear and failure, necessitating frequent replacements. This not only increases long-term expenses but also disrupts machinery operations, causing unexpected downtimes and heightened maintenance demands. Such cost-cutting measures compromise the overall efficiency and reliability of equipment e. Lack of knowledge and investment towards bearing life improvement Bearings failure results in significant unrecovered costs in lost production and equipment replacement. Proactive investment in identifying and addressing the onset of issues is crucial to maintaining asset efficiency and balancing the costs of monitoring, maintenance, and repairs. Why should you choose KG Ultra? KG Ultra bearings are meticulously designed for precision applications demanding the utmost in accuracy, speed, and rigidity. Engineered for intense, heavy-duty operations, these premium bearings have earned a global reputation for defining excellence in reliability and efficiency. By opting for KG Ultra, you gain access to:a. Extensive Range : A complete range of bearings to make your operations more competitive, productive, and profitable: b. Technical Superiority:  Focused on improving your total cost of ownership by providing: ISO tolerance class 6 ISO 492, P6, Tighter tolerance than normal Component hardness controlled to 58 – 64 HRC Component hardness controlled to 58 – 64 HRC Raw material: GCr15, equivalent to AISI 52100 and DIN 100Cr6 Leading QA systems performing 130% component checking in China and Dubai All parts and components manufactured under a single roof for total control c. ROI and Unit Economics: Bearing selection is contingent on finding the right balance between cost and life and ensuring that all bearings are fit for purpose. The below graphs on price vs quality between KG Ultra and its alternatives establishes why KG Ultra is the right choice for driving meaningful ROI and dollar savings no matter what you are using today: Fig. a. KG Ultra offers equal or better quality than economical European bearings within a 0%-20% range, at a price benefit of 20%-30%. Fig. b. KG Ultra attains near-equivalent quality to Japanese bearings within a 10%-30% range, while offering considerable cost savings of 40%-50%. Fig. c. KG Ultra offers comparable quality within 20%-40% of Premium European Bearings, with a significant price benefit of 60%-80%.d. Automated Lubrication: In association with Dropsa, we enable peak performance of your machinery by ensuring: The accurate lubricant quantity at the exact interval providing precise lubrication amounts, avoiding over or under-lubrication A continuous, automated supply of lubricant, reducing manual testing and human errors Significant savings in repair, failure, and labour costs e. Packaging Revolution: We believe that great products deserve great packaging. The new KG Ultra packaging offers:  A sleek, innovative, and informative design with a modern look for easy identification Enhanced product protection for shipping and storage, ensuring your shipment arrives in perfect condition Eco-friendly materials demonstrating our dedication to sustainability and reducing our carbon footprint Contact us for comprehensive bearing services and support Ensuring the longevity and optimal performance of your bearings begins with proper training and support. At KG, we are dedicated to delivering top-notch bearings and exceptional customer services to our valued customers by offering: Product selection support to ensure smooth operation Technical training and application engineering support Grease and oil lubrication selection and automated system installation Installation support to ensure bearing protection Condition monitoring and stock monitoring to maximize uptime Failure analysis to determine improvement opportunities Reach out today for unparalleled bearing solutions and support. Our team is ready to assist you in choosing the right bearing for your needs. Choose KG for seamless integration and continuous performance enhancements. Email us at sales@kginternational.com or WhatsApp at +971 50 700 8262 and visit our website www.kginternational.com for more details. Share this post Recent Whitepaper

Home » Whitepaper » A Critical Imperative for Maximizing Production Efficiency KG International Abstract In today’s highly competitive industrial landscape, maximizing production efficiency is of paramount importance for all industries. A critical factor influencing operational performance is the quality of fuel and oil. This white paper meticulously explores various contamination types, highlighting their implications and the imperative of sustained operational efficiency. By focusing on bulk filtration, it showcases the versatility of KG Filter Carts in enhancing performance and cost-effectiveness. This paper underscores the significance of filtration system in achieving seamless industrial operations, ensuring longevity and reliability. Type of contamination and its effects​ Effective fuel and oil management is vital to ensure the smooth operation of machinery and equipment in every industry. Failure to maintain clean fuel and oil can lead to numerous detrimental effects. This section delves into the key consequences of using contaminated fuel and oil. Type of Contaminants Effects on Fuel and Oil Effects on Engine Life Effects on Environment Particulate Potential clogging in fuel injector Likelihood of short engine life Likelihood of short engine life Water Corrodes metal parts Forms oxidation Basis of acid rain and pollution Chemical Alteration in fuel properties Corrosion of engine components Responsible for air pollution and contributes to climate change Metal Particles Decrease fuel efficiency Engine overheat, damage to fuel injectors Risks to soil, crops and live stocks Understanding clean fuel and oil Contaminant free fuel and oil is paramount to overall efficiency of engine and prolonging the lifespan of machinery. The ISO 4406 and NAS 1638 cleanliness codes offer standardized methods to evaluate fluid cleanliness. ISO 4406 provides three numerical values detailing the particle quantity in specific size ranges: 4 μm and larger, 6 μm and larger, and 14 μm and larger. In contrast, the NAS 1638 method differentially counts particles in size intervals of 5-15μm, 15-25μm, 25-50μm, 50-100 μm, and >100 μm.For many equipment, an incoming cleanliness adhering to the ISO standard is typically 22/21/18. This indicates, for a 100ml fuel sample at an ISO level of 22, that there are between 2 to 4 million particles present. However, optimal machinery operation often requires a cleanliness closer to an ISO standard of 14/13/11. Utilizing KG Filter Carts guarantees high filtration efficiency, ensuring NAS level 4 clean oil. Ensuring such cleanliness levels significantly reduces wear and tear, providing optimal equipment performance and longevity. ISO 4406 Cleanliness Code ISO Code Number No of Particles per 100ml More Than Up to and including 24 8,000,000 16,000,000 23 4,000,000 8,000,000 22 2,000,000 4,000,000 21 1,000,000 2,000,000 20 500,000 1,000,000 19 250,000 500,000 18 130,000 250,000 17 64,000 130,000 16 32,000 64,000 15 16,000 32,000 14 8,000 16,000 13 4,000 8,000 12 2,000 4,000 11 1,000 2,000 10 500 1,000 9 250 500 8 130 250 7 64 130 6 32 64 BEFORE FILTERATION AFTER FILTERATION What is bulk filtration and how does it work? Bulk filtration is a comprehensive solution designed to remove contaminants from large quantities of fuel and oil, ensuring their cleanliness and optimal quality. This process involves the use of advanced filtration systems specifically designed for high-capacity applications. The bulk filtration process typically consists of multiple stages, each targeting different types of contaminants. KG Filter Cart uses SINGLE PASS FILTRATION technique to remove all contaminants and can be utilized in both in-plant machinery and mobile equipment. Below are the stages of KG Bulk Filtration systems: Main filtration in this stage, the fuel or oil flows through fine filtration media, such as high-quality filter cartridges. This stage consists of particulate filter designed to capture smaller particles, including those invisible to the naked eye, ensuring the fuel or oil is thoroughly purified. Water absorbing technology Water contamination is a common issue in fuel and oil systems. KG Filter Carts incorporate specialized technology to separate and remove free water from the fuel or oil. Bulk filtration streamlines and expedites the cleaning process, offering a remarkably efficient solution. Traditionally, users would invest nearly half a day in cleansing equipment or storage tanks, incurring substantial labor expenses while grappling with operational downtime, untidy premises, and unsafe work conditions. KG International has ingeniously engineered systems for uninterrupted operation. These systems seamlessly integrate into prevailing fuel or oil storage and distribution frameworks, ensuring a smooth implementation devoid of any disruptive factors. The procedure of flushing is remarkably simple: insert the suction end of the hose at the tank’s inner base and the delivery end at a midpoint within the tank, initiate the pump and clean the entire tank within minutes. Product range and use cases KG Bulk Filtration solutions offer a diverse range of products that cater to unique demands, ensuring clean fuel and oil, improving equipment performance, and reducing overall maintenance costs. Every product in our range is meticulously crafted to fulfil these objectives. The use of premium-grade filter media guarantees high filtration efficiency and consistency in performance across multiple applications by effectively capturing particulate, water, and other contaminants. The pump used in the system is manufactured by an Italian company, PUS. With the capacity of 25 LPM, the pump can be used to filter Diesel, Lube Oil, Hydraulic or Gear Oil. A point to remember is when the liquid is changed, the filter needs to be changed as well.The filters used in filtration systems are made in collaboration with the HIFI Filters, known for being leaders in filtration solutions. Products Description Operating Pressure Burst Pressure Media Use Cases SHR 536F04 V β(4μ) ≥ 2000 24 bar 55 bar FiberGlass Automotive, Industrial, Commercial vehicles, Construction and Mining SHR 536F07 V β(7μ) ≥ 2000 24 bar 55 bar FiberGlass Automotive, Industrial, Commercial vehicles, Construction, Mining and Steel SHR 536F25 V β(25μ) ≥ 2000 24 bar 55 bar FiberGlass Automotive, Industrial, Commercial vehicles, Construction, Mining and Steel SNR 536AB0 V Water absorbing Absorbent Coupled with all the filters to remove free water from fuel and oil Features of KG Filter Carts Single Pass Filtration: The KG Filter Cart cleans the fuel in a single pass, significantly reducing the time spent in flushing oil. This ensures that filtration is only required when putting fuel or oil into service, thus minimizing additional cleaning time. Highest Beta Ratio in the market: Beta ratio is a crucial