Page 59 - FoodFocusThailand No.246 October 2026

SOURCE OF ENGINEER OF ENGINEER
SOURCE

END-OF-LINE AUTOMATION:

UNLOCKING HIDDEN COSTS WITH

LOW-MAINTENANCE ENGINEERING SOLUTIONS

Whether it is a packaging station, a palletizing station, or an AS/RS, one characteristic unites every station
at the end of a production line: it is an area of continuous dynamic movement. This holds true whether it is
an AS/RS crane travelling up and down, a palletizing robot arm rotating back and forth repeatedly, or the
mechanisms within a packaging station operating at high cycle speeds.

Tens of thousands of repetitive movements per day, carried solid lubricant is gradually released in precisely the amount the
out under this level of intensity, cause components to wear contact surface requires, with no need for external oil or grease
and fail frequently. When any single point malfunctions, the whatsoever. Because there is no external lubricant to attract
impact rarely stays contained — it typically escalates into a dust and debris, the contamination build-up of contamination,
full line breakdown, bringing with it hidden costs that are often which is a leading cause of premature wear in conventional
overlooked. metal bearings is virtually eliminated in this class of material.
This property has been proven across a wide range of
The True Cost Lies Beyond the Quotation real-world applications, particularly in industries that regularly
The initial purchase price of an automation system is only encounter moisture or cleaning chemicals. Plastic bearings
the starting point of the true cost. Beyond it lies recurring are corrosion-free and resist chemical attack far more
maintenance expenditure, which covers lubricants, technician effectively than metal. Furthermore, even under heavy loads
labour, and the downtime incurred every time the machine must and continuous high-speed operation, this class of material
stop for servicing. Accumulated over years of operation, these maintains a consistent coefficient of friction throughout its
costs invariably grow far beyond initial estimates. service life.
Beyond that lies a cost that is even harder to forecast: losses
from unplanned downtime. Even a brief stoppage during a peak Predictive Service Life Calculation —
production period can cause damage far exceeding the value Eliminating Wasted Component Replacement
of the failed component itself. Because the true service life A key advantage that resolves the challenge of managing
of a component under such demanding conditions is difficult replacement timing is the ability to accurately calculate a
to predict with confidence, manufacturers are left choosing bearing’s service life in advance through an online calculation
between two strategies, each carrying its own hidden cost: tool. By referencing real-world operating parameters such
replacing components pre-emptively on a fixed schedule — as load, speed, and temperature, engineering teams can
which may shorten a component’s working life before it reaches determine replacement intervals with precision — removing
the end of its useful life — or running components until they the uncertainty of replacing components too early while they
fail in the field, which risks an unplanned production stoppage. remain serviceable, or facing the risk of sudden failure.
When evaluating the long-term cost structure of an end-of-
Engineering Components for Minimal Maintenance line system, components often dismissed as minor details —
A sound strategy for managing Total Cost of Ownership (TCO) such as bearings — emerge as critical variables with a direct
should therefore begin with selecting mechanical components impact on a production line’s net profit. Prudent, sustainable
engineered to withstand demanding operating conditions and investment therefore requires looking beyond the price stated
to minimise maintenance requirements from the very first day on an initial quotation, and instead focusing on the Total Cost of
of system design. This is precisely where motion plastics play Ownership. In the end, an engineering solution that is durable,
a critical engineering role. offers precise service-life calculation tools, and reduces the
burden of maintenance is consistently the most cost-effective
Dry-Running Plastic Bearings — choice when the system must perform under intense and
No Lubrication Required demanding operating conditions.
What allows this class of material to operate without lubrication
throughout its entire service life lies in its microscopic structure.
It is composed of a base polymer that carries the load and resists
wear, reinforcing fibres that add mechanical strength, and a More Information Service Info C009
solid lubricant embedded within microscopic pockets distributed
evenly throughout the material. As the component moves, the

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