Thanks to lubrication-free polymer bearings, French manufacturer Sunilux saves around 20,000 hours of maintenance work and 25,000 euros in lubricating grease

Keeping service costs low in times of shortages of skilled personnel: Sunilux, the French manufacturer of bioclimatic pergolas, achieves this by using lubrication-free and maintenance-free polymer bearings from igus. The company can offer an above-average ten-year guarantee on its patio roof covering while simultaneously saving 20,000 hours of maintenance work and €25,000 in grease costs.

Finally, out onto the terrace to enjoy an ice cream in the sun. But then, all of a sudden, there’s a downpour. To ensure that such a change in the weather doesn’t spoil your fun, the French company Sunilux has developed the Solembra electric pergola for use in homes and catering establishments. Their aluminium slats can be moved at the touch of a button, creating a closed roof in a matter of seconds that provides protection from the sun and rain. A system with which Sunilux is enjoying increasing success on the market. However, this also presents challenges. For example, the more pergolas there are, the more important it is that they are reliable. Otherwise, service costs would quickly skyrocket. “This means we need low-maintenance components,” says Adrien Dufour, Head of R&E and Quality at Sunilux. “The bearings for the adjustable slats, for example, are crucial.” This is because they are exposed to the elements, damp, frost and UV radiation all year round.

Plastic bearings instead of metal ones: lubrication-free, UV-resistant, corrosion-free and frost-resistant

“We have decided to do away with traditional metal bearings and instead rely on igus’ corrosion-free and maintenance-free polymer bearings,” says Adrien Dufour. “A decision we never regretted. This has enabled us to reduce our service costs significantly. At the same time, we are able to offer our customers an exceptionally long ten-year guarantee.” Sunilux uses plain bearings and thrust washers made from iglidur G, as well as double flange bearings made from iglidur M250, in its electric pergola. Each of the pergola’s 30 slats rotates on a stainless-steel axis via two bearings as it opens and closes. In addition, there are 30 other bearings made of high-performance plastic in a movable trough element on each of the two sides of the pergola. This follows the movement of the slats and helps to ensure that the system is sealed tight against rain when closed. Polymer bearings are suitable for maintenance-free continuous operation for a number of reasons. For one thing, unlike metal bearings, they do not require lubrication. Integrated solid lubricants ensure low-friction dry operation. Furthermore, they are corrosion-free in the rain and suitable for continuous use at extreme temperatures ranging from -40°C to +130°C, while being resistant to UV radiation. At the same time, they are resistant to dirt because there is no lubricating film to which particles could adhere.

“The polymer bearings are of strategic importance to us”

By using polymer bearings, Sunilux achieves a double saving. If service engineers had to relubricate the bearing points once a year – as would be the case with many metal alternatives, according to Sunilux – this would amount to a total of around 20,000 working hours for all the currently installed systems over the ten-year guarantee period. In addition, there are savings of around 25,000 euros on lubricating grease. “The maintenance-free polymer bearings are therefore of strategic value to us,” emphasises Adrien Dufour. “They significantly reduce the workload on service staff and cut material costs – a critical factor given the growing shortage of skilled workers.”