Overview
Greasable and maintenance-free casters serve different purposes. Confusion between the two leads to poor performance and unnecessary maintenance.
Understanding the design differences helps reduce downtime and labor cost.
How Greasable Casters Work
Greasable casters use zerk fittings to lubricate swivel raceways, axles, and sometimes wheel bearings. Most designs include two to three grease points.
- Open raceways
- Periodic lubrication required
- Performance depends on maintenance discipline
Without consistent greasing, performance degrades rapidly.
How Maintenance-Free Casters Work
Maintenance-free casters use sealed or enclosed raceways and pre-greased bearings. Many designs are kingpinless or use reinforced raceway construction.
- Sealed ball bearings
- No grease fittings
- Designed for continuous operation
These casters are commonly used in high-duty and ergonomic applications.
Maintenance-Free vs Greasable Casters
| Factor | Greasable Casters | Maintenance-Free Casters |
|---|---|---|
| Maintenance labor | Required | None |
| Downtime risk | Higher if neglected | Lower |
| Environmental sealing | Open | Sealed |
| Duty cycle | Intermittent | Continuous |
| Initial cost | Lower | Higher |
| Lifetime cost | Higher | Lower |
How to Choose Correctly
- Choose greasable casters where maintenance is controlled and scheduled
- Select maintenance-free casters for continuous operation
- Consider ergonomics and push force requirements
- Standardize by application to reduce variability
Maintenance strategy is part of the broader discussion in the 2026 Industrial Forecast.