How FMS Africa Helped Slash
Gearbox Costs by 50%​

Introduction

In the mining industry, sinter plants form the operational backbone. These facilities process iron ore fines into a sintered product, which is then used as feedstock for blast furnaces. Reliability is everything. But sinter plants operate in punishing conditions—high temperatures, corrosive dust, and heavy mechanical loads. One of the most vulnerable components? The steel belt gearboxes.

At a prominent South African sinter plant, these gearboxes were deteriorating rapidly due to continuous exposure to fine sinter dust. Breakdowns weren’t just inconvenient—they risked halting the entire production line, incurring costs far beyond equipment replacement. That’s when the plant turned to FMS Africa for a robust, proactive solution.

 

The Intervention

FMS Africa brought its expertise in contamination control to the fore, implementing a suite of integrated solutions centered around the Des-Case RMF Offline Heated Filtration System (OLUHS). This system was specifically designed to tackle the fine particulate contamination inherent to sinter plant operations.

Key components included:

• Glass fiber filter elements: Capable of capturing ultra-fine, abrasive particles, especially chromium-laced sinter dust that accelerates gear and bearing wear.
• Oil Quality Sensor (OQS) and Contamination Monitoring Sensor (CMS): Provided real-time insight into lubricant health and particulate levels.
• Desiccant breathers (ACM61 and IsoLogic®): Prevented moisture and airborne contaminants from entering the gearbox housing.
• 3D Bullseye® visual oil analysis tools: Offered instant visual assessments of oil clarity and condition.

These systems were seamlessly integrated using adapter kits and drain ports, ensuring minimal downtime during implementation.

 

Quantifiable Impact

The results were not just visible—they were measurable, and fast:

• ISO Cleanliness Improvement: Within one week, oil cleanliness improved from a hazardous 23/22/19 to a benchmark-setting 15/13/10.
• Annual Cost Reduction: Gearbox operational costs dropped from $18,000 to $9,000 per year.
• Return on Investment: The $26,000 investment for two gearboxes reached payback in just 17 months.
• Five-Year Financial Returns:

  * Net Present Value (NPV): $34,751
  * Internal Rate of Return (IRR): 208%

 

Moreover, iron wear reduced by a factor of 2.5, indicating extended mechanical life and reduced failure risk. This wasn’t just a win in cost savings—it was a win in reliability, safety, and uptime.

 

Bottom Line

This case proves that modest investments in proactive maintenance and filtration can yield massive long-term savings.

FMS Africa’s targeted approach not only protected critical assets but unlocked significant financial benefits for the client.

For any heavy industrial operation dealing with contamination-related wear, this success story stands as a compelling blueprint for cost-effective reliability engineering.

 

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