In a joint research project funded by the German Federal Ministry of Education and Research, a new bearing and sealing concept for highly loaded, grease lubricated bearings operating under adverse surrounding conditions was developed in order to increase bearing life expectancy and significantly decrease grease consumption. Roller bearings in continuous casting plants were used as a representative example. Apart from high loads, bearings in these surroundings are subject to contamination by process water and dirt particles. Following a load and stress analysis, model greases were developed, and based on model tests and calculations, constructional optimisations were implemented. The project was carried out in close interdisciplinary collaboration of the bearing, seal and lubricant manufacturers, the plant operator and research institutes.