At the Bearing & Power Transmission World Meetings 2025, David Beattie and Rhys Morgan from DASH ENGINEERING delivered an eye-opening presentation on why grease-filled labyrinth seals often fail in real-world applications. Drawing on more than 13 years of bearing failure analysis and over 1,000 conveyor pulley inspections, they revealed that the primary cause of bearing failures is contamination ingress – not misalignment, overload, or poor quality as often assumed.
Through practical case studies and scientific testing, including a collaboration with a Western Australian university, the team proved that grease migration occurs due to the Weissenberg effect. Instead of being expelled outward as commonly believed, grease actually moves inward toward the shaft, carrying dirt, water, and contaminants directly into the bearing. This discovery explains why traditional “three barrier” sealing methods fail and why catastrophic bearing failures are so common in industries such as mining, power, and materials handling.
The presenters also showcased DASH ENGINEERING’s engineered sealing solutions, including the SAPO seal and G-Series seal, designed to eliminate excuses, extend bearing life, and reduce costly downtime. With proven success across major mining operations like Rio Tinto, these solutions have already saved millions in avoided failures.
Watch this presentation to understand the science behind grease migration and discover how new seal designs are transforming reliability in harsh industrial environments.
