Choosing the Right Roller Chain: Why Total Cost of Ownership Matters
When purchasing a new roller chain, it can be tempting to focus primarily on the upfront cost. You might opt for the cheapest option, buy a large quantity, and assume the job is done. But is it really?
For many industrial chain buyers, the real expense lies not in the initial price but in the ongoing operating costs. Opting for a low-cost chain often leads to higher expenses in the long run. This is where considering the total cost of ownership (TCO) becomes critical.
Matching the Chain to the Application
Different materials handling applications demand different types of industrial chains. Selecting the wrong chain can lead to higher maintenance costs, reduced efficiency, and premature failure. Here are some examples:
Maintenance-Free Chains: Ideal when lubrication isn’t feasible or practical.
Double Capacity Chains: Designed to handle higher loads and avoid overload failures.
Corrosion-Resistant Chains: Essential for damp or harsh environments.
Even small adjustments can have a significant impact. For instance, consider the chain length you purchase.
Choosing Pre-Cut Roller Chains
Most roller chains are sold in standard boxed lengths, meaning longer chains often require joining multiple shorter lengths with connecting links. This practice can lead to:
Reduced Strength: Connecting links can weaken the chain, sometimes reducing tensile strength by as much as 20%.
Increased Waste: Unused off-cuts can add unnecessary costs.
A better solution is to purchase pre-cut roller chains tailored to your exact needs. If your drive or conveyor requires a 7.2-meter chain, you receive it at the precise length—eliminating cutting, waste, and the risk of compromised strength.
Optimizing Lubrication
Lubrication is critical for traditional roller chains but can be a hidden cost driver. High-quality lubricant starts at around £6.00 per liter, and whether applied manually by skilled technicians or through automated systems, it incurs additional expenses.
In contrast, lube-free chains eliminate the need for frequent lubrication. Although their upfront cost is higher, they often prove more cost-effective over time, especially in applications where lubrication is impractical or labor-intensive.
Reducing Replacement Costs
Frequent chain replacement is one of the largest expenses in many roller chain applications. Beyond the cost of the new chain, replacements require labor, planning, and operational downtime, all of which increase TCO.
Consider this real-world example:
A waste handling company used a 1 ¼-inch pitch roller chain costing £190 that broke monthly, incurring £1000 in downtime and replacement costs. Due to space restrictions, upgrading to a duplex chain wasn’t feasible. Instead, they replaced it with a double capacity chain priced at £450. While the new chain cost more than double the original, it ran trouble-free for six months—resulting in significant cost savings and increased productivity.
The Value of Quality and Innovation
Reputable chain manufacturers prioritize high-quality materials and advanced manufacturing techniques. However, true value often comes from manufacturers who think differently and provide tailored solutions.
When evaluating roller chain options, avoid settling for off-the-shelf solutions. Instead, calculate the overall costs and explore bespoke solutions tailored to your specific needs. While customized chains may have a higher upfront cost, they often deliver:
Reduced Downtime
Improved Product Performance
Lower Total Cost of Ownership
Conclusion
Choosing the right roller chain is about more than just finding the cheapest option. By focusing on TCO and considering factors such as pre-cut lengths, lubrication requirements, and durability, you can make smarter purchasing decisions that benefit your operations in the long term.
Partnering with a supplier who offers innovative, tailored solutions can significantly enhance your operations—delivering better performance, reduced maintenance, and lasting value. Remember, the best deal isn’t always the cheapest, it’s the one that meets your needs for the long haul.
GIDI CHAIN LIMITED supply lots of roller chain, conveyor chain, Leaf Chain, welded chain, forged chain, Palm Oil Mill Chain, Hoisting Chain,Mine and Metallurgy Chain, etc. totaling over 3000 varieties. and 90% of chains are exported to worldwide, Which mainly export to Southeast Asia, European, North America, South America. Chains are welcomed by customers with the excellent quality. Our company owns more than 100 sets of advanced and professional manufacturing equipment, Perfect and rigorous QC system is implemented in every process from material purchasing to finished products packaging. Also, we have passed the ISO9001: 2015 Quality Management System Certification.
More Detail : www.gidi-chain.com