Companies can significantly reduce their staffing costs associated with machine greasing by transitioning to Vesconite’s low-maintenance bearing solutions. This is according to Vesconite Bearings technical consultant Eddie Swanepoel, who conducted a greasing cost analysis for a South African client with a large machine fleet.
Greasing costs can quickly escalate in operations where multiple machines are in service, each with a high number of grease points. These costs are further compounded when lubrication must occur daily or several times a week, Swanepoel explains.
“This alone justifies the investment in Vesconite bushings,” he states. “Our client was able to clearly see the savings in labour, time, and maintenance-related downtime by switching to bushings that require little or no lubrication.”
Swanepoel notes that greasing-related costs may be even more significant for companies operating in highly regulated or technically advanced environments. In such operations, staff tend to be more specialised, and systems are often in place to prevent equipment failure due to missed or improper lubrication.
“Companies with higher-paid technical staff, stringent maintenance protocols, and sophisticated lubrication systems stand to benefit even more from the switch,” he says.
The staffing costs associated with greasing depend on the lubrication model adopted by a company. Swanepoel identifies three common models in industry:
- The dedicated lubrication technician model, where a staff member is assigned exclusively to greasing tasks.
- The multi-skilled mechanic model, where a maintenance professional handles lubrication as part of broader equipment upkeep.
- The operator model, in which machine operators take responsibility for greasing their own equipment.
Each model has its own cost structure, influenced by country-specific wage rates, staff seniority, and job descriptions. However, in all cases, lubrication contributes a non-trivial portion of overall maintenance labour expenses.
“Greasing is not just about squeezing grease into a fitting,” Swanepoel says. “It involves identifying the right grease, accessing grease points safely, applying the correct amount, and ensuring the lubrication intervals are met consistently. It takes time, planning, and resources.”
He adds that labour is not the only cost incurred in using traditional greased bushings. There are other indirect costs such as equipment downtime when greasing is missed or performed incorrectly, wear-related failures, the price of grease itself, and expenses related to lubrication infrastructure—such as grease lines, zerks, manifolds, and automated lubrication systems.
“Each of these costs becomes less relevant when using Vesconite bushings,” says Swanepoel. “Because they are self-lubricating, these bushings reduce or completely eliminate the need for routine greasing.”
In addition to labour cost savings, Vesconite bushings offer extended operational lifespans, improved reliability, and the potential for longer equipment warranties. Maintenance intervals can be extended, and machine availability can be increased—translating into improved profitability.
“Reducing maintenance requirements has real commercial value,” Swanepoel concludes. “It frees up skilled personnel for more critical work, reduces consumable costs, and cuts down on unplanned downtime. Our bushings are helping clients lower their total cost of ownership across a wide range of industries.”
Vesconite bushings are currently used in applications where reliability, durability, and low maintenance are priorities—including mining, construction, agriculture, marine, and materials handling sectors.
