{"id":1590275,"date":"2026-10-16T19:25:23","date_gmt":"2026-10-16T16:25:23","guid":{"rendered":"https:\/\/steiner.com.ua\/?p=1590275"},"modified":"2026-10-16T19:26:36","modified_gmt":"2026-10-16T16:26:36","slug":"originalni-chy-analogovi-zapchastyny","status":"publish","type":"post","link":"https:\/\/steiner.com.ua\/en\/originalni-chy-analogovi-zapchastyny\/","title":{"rendered":"Genuine or aftermarket spare parts: real risks and real savings"},"content":{"rendered":"<p class=\"wp-block-paragraph\">There is no clear-cut answer such as \u2018only the original\u2019 or \u2018a generic part is just as good\u2019. The decision depends on the role the part plays in the equipment: whether it comes into contact with the product, whether it affects process safety, and what the cost of its failure would be.<\/p><p class=\"wp-block-paragraph\">For general-purpose parts, a high-quality alternative from a trusted manufacturer is often a sensible way to save money. For parts that come into contact with the product or determine the line\u2019s integrity and sterility, savings on the purchase price are usually offset by more costly downtime, defects and audit risks.<\/p><h2 class=\"wp-block-heading\"><strong>Why is this issue arising right now?<\/strong><\/h2><p class=\"wp-block-paragraph\">Manufacturers of food, dairy and pharmaceutical products operate in an environment of high energy, logistics and labour costs. Spare parts are one of the few areas where a purchaser can see immediate savings: a generic seal can cost 30\u201360 per cent less than the original.<\/p><p class=\"wp-block-paragraph\">The problem is that whilst these savings are immediately apparent, the costs arising from a substandard part emerge later and are charged to other cost centres: repairs, downtime, batch write-offs and unscheduled cleaning. Therefore, it is not the price of the part that should be compared, but the total cost of its use.<\/p><h2 class=\"wp-block-heading\"><strong>Three classes of spare parts: varying levels of risk<\/strong><\/h2><p class=\"wp-block-paragraph\">A practical approach is to categorise spare parts by criticality.<\/p><ol class=\"wp-block-list\"><li><strong>Critical: contact with the product and process safety.<\/strong> Valve seals and diaphragms, gaskets for plate heat exchangers, pump mechanical seals, parts for dosing units and filling valves, and components of aseptic lines. Failure of such parts jeopardises product safety, leak-tightness and sterility.<\/li>\n\n<li><strong>Conditionally critical: these affect operation but not the product.<\/strong> Drive components, sensors, pneumatic systems, and control system components. A failure halts the production line but does not pose a direct risk to the product.<\/li>\n\n<li><strong>General-purpose.<\/strong> Standard bearings, fasteners, belts, process media filters, standard rings from unmarked zones. These are manufactured to international dimensional standards, and a high-quality equivalent from a well-known manufacturer is generally considered to be of equal value.<\/li><\/ol><p class=\"wp-block-paragraph\">This classification allows us to avoid generalised debates about spare parts and instead make decisions for each group separately.<\/p><h2 class=\"wp-block-heading\"><strong>Real risks associated with equivalent spare parts<\/strong><\/h2><p class=\"wp-block-paragraph\"><strong>Materials that do not meet the requirements for contact with foodstuffs.<\/strong> Elastomers (EPDM, FKM, NBR, silicone) for food processing equipment must have certification confirming their suitability for contact with food \u2014 for example, compliance with Regulation (EC) No 1935\/2004 or FDA 21 CFR 177.2600. Cheap alternatives often lack such documentation or it does not relate to the specific batch. For organisations with HACCP, IFS or BRCGS certification, this poses a direct risk of non-conformities being identified during an audit.<\/p><p class=\"wp-block-paragraph\"><strong>Incompatibility with CIP cleaning agents.<\/strong> Alkali, nitric acid, peracetic acid and high cleaning temperatures rapidly degrade an incorrectly selected elastomer. A seal may look identical, but after a few weeks it swells, cracks or loses its elasticity.<\/p><p class=\"wp-block-paragraph\"><strong>Geometry and tolerances.<\/strong> Heat exchanger gaskets, profiled valve seals and mechanical seal rings are designed for specific applications. Deviations of a tenth of a millimetre result in an imperfect fit, leaks, areas that are difficult to clean during CIP, and a breeding ground for microorganisms.<\/p><p class=\"wp-block-paragraph\"><strong>Reduced service life.<\/strong> A generic part may last a month where the original lasts a year. Every replacement involves a production line shutdown, work by maintenance staff, re-cleaning and restarting.<\/p><p class=\"wp-block-paragraph\"><strong>Equipment warranty and certification.<\/strong> Fitting non-original parts may affect the equipment manufacturer\u2019s warranty obligations. For equipment with hygiene certification (EHEDG, 3-A) and in the pharmaceutical sector with validated GMP processes, replacing a component with an untested alternative may require a change control procedure.<\/p><p class=\"wp-block-paragraph\"><strong>Traceability.<\/strong> During an incident investigation or audit, it is necessary to confirm exactly which part was fitted to the equipment, from which batch and with which certificate. An anonymous alternative from a marketplace does not provide such traceability.<\/p><h2 class=\"wp-block-heading\"><strong>Real savings: how to calculate the total cost<\/strong><\/h2><p class=\"wp-block-paragraph\">Instead of the price of a part, it is worth comparing the annual cost of its use:<\/p><p class=\"wp-block-paragraph\">C_{year} = N \\cdot (P + L + D)<\/p><p class=\"wp-block-paragraph\">where N is the number of replacements per year; P is the price of the part; L is the cost of replacement work; D is the loss due to line downtime during replacement (unproduced output, re-cleaning, restart).<\/p><p class=\"wp-block-paragraph\"><strong>Example in notional units.<\/strong> Pump seal kit: the original costs 100, the alternative 60. The original lasts 12 months, the alternative 6. Labour for replacement: 40; losses due to line downtime: 200.<\/p><ul class=\"wp-block-list\"><li>Genuine part: 1 replacement per year \u00d7 (100 + 40 + 200) = 340.<\/li>\n\n<li>Aftermarket part: 2 replacements per year \u00d7 (60 + 40 + 200) = 600.<\/li><\/ul><p class=\"wp-block-paragraph\">The part is 40 per cent cheaper, but its annual running cost is 76 per cent higher. And this does not take into account the risk of a defective batch or an unscheduled emergency shutdown.<\/p><p class=\"wp-block-paragraph\">The formula works the other way round too. If the alternative has the same service life and replacement does not halt the production line, the savings are real. Therefore, the calculation should be carried out for each group of parts using the company\u2019s own figures.<\/p><h2 class=\"wp-block-heading\"><strong>When an alternative part is justified<\/strong><\/h2><ul class=\"wp-block-list\"><li>The part belongs to the third class: standard bearing, fastener, belt, process medium filter.<\/li>\n\n<li>The equivalent part is manufactured by a well-known manufacturer, rather than an unknown supplier without documentation.<\/li>\n\n<li>For parts that come into contact with the product, there is a material certificate and a declaration of conformity for the specific batch.<\/li>\n\n<li>The equipment is no longer under warranty, and the manufacturer does not stipulate the use of original parts only.<\/li>\n\n<li>The alternative part has undergone trial operation on a single unit of equipment prior to widespread implementation.<\/li><\/ul><h2 class=\"wp-block-heading\"><strong>When it is better to stick with the original<\/strong><\/h2><ul class=\"wp-block-list\"><li>The part comes into contact with the product or determines the line\u2019s integrity and sterility.<\/li>\n\n<li>The equipment is under warranty or holds hygiene certification.<\/li>\n\n<li>Pharmaceutical production with a validated process.<\/li>\n\n<li>Failure of the part halts a key production line during peak demand.<\/li>\n\n<li>The equipment manufacturer has changed the design, and the replacement part may only be compatible with the previous version.<\/li><\/ul><h2 class=\"wp-block-heading\"><strong>Checklist: how to vet a spare parts supplier<\/strong><\/h2><ol class=\"wp-block-list\"><li>Can the supplier confirm the part\u2019s origin and manufacturer?<\/li>\n\n<li>Is there a material certificate and a declaration of conformity for food contact specifically for this batch?<\/li>\n\n<li>Is the material grade specified, along with its resistance to your cleaning agents and temperatures?<\/li>\n\n<li>Does the part correspond to the current design version of your equipment (based on the serial number or drawing)?<\/li>\n\n<li>Does the supplier offer a warranty, and do they have experience of using the part on similar equipment?<\/li>\n\n<li>Can traceability be ensured: batch number, delivery date, documentation?<\/li>\n\n<li>What is the actual delivery time, and is there stock available?<\/li><\/ol><p class=\"wp-block-paragraph\">If you answer \u2018no\u2019 or \u2018don\u2019t know\u2019 to three or more questions, the cost saving is not worth the risk.<\/p><p class=\"wp-block-paragraph\">The choice between an original part and an equivalent is not a matter of principle, but a matter of cost-benefit analysis and the criticality of the part. For standard, general-purpose parts, a high-quality equivalent can represent a sensible saving. For parts that come into contact with the product and determine process safety, it is not the price that is decisive, but the service life, documentation and traceability.<\/p><p class=\"wp-block-paragraph\">Steiner supplies original spare parts for pumps, valves, heat exchangers and process lines, and also helps to build up a stock of critical spare parts so that replacement does not result in prolonged downtime.<\/p>","protected":false},"excerpt":{"rendered":"<p>\u041e\u0434\u043d\u043e\u0437\u043d\u0430\u0447\u043d\u043e\u0457 \u0432\u0456\u0434\u043f\u043e\u0432\u0456\u0434\u0456 \u00ab\u0442\u0456\u043b\u044c\u043a\u0438 \u043e\u0440\u0438\u0433\u0456\u043d\u0430\u043b\u00bb \u0430\u0431\u043e \u00ab\u0430\u043d\u0430\u043b\u043e\u0433 \u043d\u0435 \u0433\u0456\u0440\u0448\u0438\u0439\u00bb \u043d\u0435\u043c\u0430\u0454. \u0420\u0456\u0448\u0435\u043d\u043d\u044f \u0437\u0430\u043b\u0435\u0436\u0438\u0442\u044c \u0432\u0456\u0434 \u0442\u043e\u0433\u043e, \u044f\u043a\u0443 \u0440\u043e\u043b\u044c \u0434\u0435\u0442\u0430\u043b\u044c \u0432\u0456\u0434\u0456\u0433\u0440\u0430\u0454 \u0432 \u043e\u0431\u043b\u0430\u0434\u043d\u0430\u043d\u043d\u0456: \u0447\u0438 \u043a\u043e\u043d\u0442\u0430\u043a\u0442\u0443\u0454 \u0432\u043e\u043d\u0430 \u0437 \u043f\u0440\u043e\u0434\u0443\u043a\u0442\u043e\u043c, \u0447\u0438 \u0432\u043f\u043b\u0438\u0432\u0430\u0454 \u043d\u0430 \u0431\u0435\u0437\u043f\u0435\u043a\u0443 \u043f\u0440\u043e\u0446\u0435\u0441\u0443 \u0456 \u0441\u043a\u0456\u043b\u044c\u043a\u0438 \u043a\u043e\u0448\u0442\u0443\u0454 \u0457\u0457 \u0432\u0456\u0434\u043c\u043e\u0432\u0430. \u0414\u043b\u044f \u0434\u0435\u0442\u0430\u043b\u0435\u0439 \u0437\u0430\u0433\u0430\u043b\u044c\u043d\u043e\u0433\u043e \u043f\u0440\u0438\u0437\u043d\u0430\u0447\u0435\u043d\u043d\u044f \u044f\u043a\u0456\u0441\u043d\u0438\u0439 \u0430\u043d\u0430\u043b\u043e\u0433 \u0432\u0456\u0434&#8230;<\/p>","protected":false},"author":6,"featured_media":1590276,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[189],"tags":[],"class_list":["post-1590275","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-stattya"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v24.6 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>\u041e\u0440\u0438\u0433\u0456\u043d\u0430\u043b\u044c\u043d\u0456 \u0447\u0438 \u0430\u043d\u0430\u043b\u043e\u0433\u043e\u0432\u0456 \u0437\u0430\u043f\u0447\u0430\u0441\u0442\u0438\u043d\u0438 \u0434\u043b\u044f \u0445\u0430\u0440\u0447\u043e\u0432\u043e\u0433\u043e \u043e\u0431\u043b\u0430\u0434\u043d\u0430\u043d\u043d\u044f | Steiner<\/title>\n<meta name=\"description\" content=\"\u0410\u043d\u0430\u043b\u043e\u0433 \u0434\u0435\u0448\u0435\u0432\u0448\u0438\u0439 \u0443 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