38 | Plant & Works Engineering www.pwemag.co.uk June/July 2025 Special Focus Seals, Bearings and Lubrication According to Siemens report The true cost of downtime, the annual cost of an idle production line at a major automotive facility has surged to $695 million — one and a half times higher than five years ago. In heavy industry, downtime now costs $59 million annually, a 1.6-fold increase since 2019. While bearing failures are relatively rare, improper lubrication remains a key contributor. Choosing between grease and oil isn’t straightforward — it depends on factors such as speed, load, temperature, orientation, and contamination. These rising costs underscore just how critical it is to prevent avoidable equipment failures — but how often do production managers consider the critical role of industrial bearings in ensuring equipment longevity? When applying industrial bearings, few choices are as important as the choice between grease and oil lubrication. Grease and oil share the same fundamental purpose, and each play an essential role in reducing friction, minimising wear and extending bearing life. That said, the conditions in which they operate best are very different. Put simply, making the wrong bearing lubrication choice can lead to overheating, premature failure or unplanned downtime. In order to avoid these consequences, let’s look at how production managers can choose the best lubricant — and avoid the cost of equipment downtime. Where grease excels Grease has a thicker consistency than oil. It is usually a base oil suspended in a soap-like thickener, which helps it stay in place more easily — especially in vertically mounted or hard-to-reach locations. These characteristics make grease ideal for applications like electric motors, conveyor systems or food processing equipment where protection from washdown or particles is essential. Grease also acts as a sealant, helping to keep out dirt, moisture and other contaminants. It is typically easier to apply and less prone to leakage, which makes it a costeffective solution for sealed or shielded bearings that aren’t regularly maintained. Grease is often the preferred choice in applications that require simplicity, longer service intervals or operate in environments Choosing the right lubricant for your application Chris Johnson, managing director of bearing specialist SMB Bearings, explores the advantages and limitations of each lubrication method.
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