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Challenge
A large feed mill was facing recurring issues with its pelleting machine. Specifically, the roller bearings of their feed pellet maker had to be frequently replaced, despite regular relubrication using conventional lithium grease. The impact on their operations included:
- Frequent production downtime, up to 18 times per year, due to bearing failure and the subsequent replacement process.
- High grease consumption, with the mill using at least 48 kg of grease per month, leads to increased operational costs.
The root cause of these issues stemmed from the inability of the conventional lithium grease to withstand the demanding conditions of the pelleting process. This resulted in premature bearing failure and more frequent relubrication requirements, disrupting production and inflating maintenance costs.
Our Solutions
Upon assessing the situation, Fluid Solutions’ lubrication experts recognized that the conventional lithium grease being used lacked the extreme pressure (EP) and water washout resistance properties to provide adequate protection for the bearings under the pelleting machine’s heavy load. We recommended switching to Syntech Food Lube CSCM 2, a premium calcium sulfonate complex grease. This product was selected because of its superior properties, including:
- Excellent extreme pressure (EP) properties, which enhance the bearing’s ability to carry heavier loads without breaking down.
- Superior water washout and steam resistance, crucial for ensuring the grease remains effective even in wet or humid conditions.
- High operating temperature capability, which makes it suitable for the heat generated during the pelleting process.
This solution was specifically chosen to address the challenges of roller bearing lubrication in the demanding environment of a feed mill. By switching to Syntech Food Lube CSCM 2, the feed mill could expect improved bearing life, reduced relubrication intervals, and enhanced production efficiency.
Impact
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Implementing Syntech Food Lube CSCM 2 had a significant impact on the feed mill’s operations. The new bearing maintenance routine using this calcium sulfonate complex grease resulted in:
- Reduced production downtime: The need to replace roller bearings dropped from 18 times per year to only 8 times, significantly reducing disruptions and improving productivity.
- Lower grease consumption: The mill’s grease usage decreased from 48 kg to just 16 kg per month, as the relubrication schedule shifted from daily to weekly. This not only lowered operating costs but also extended the intervals between bearing replacements, further contributing to operational efficiency.
The superior load-carrying capacity and oxidation resistance of the calcium sulfonate complex grease provided better protection for the roller bearings, leading to a longer bearing life and reduced chances of bearing failure. This ultimately helped the feed mill streamline its production process, enhance overall efficiency, and cut down on both maintenance time and costs.
Product Information
Syntech Food Lube CSCM 2 is a premium-quality, calcium sulfonate complex grease with excellent stability and extreme pressure capabilities. Designed to extend relubrication intervals, this grease provides superior protection in a variety of applications. Its exceptional load-carrying capacity and resistance to water and steam washout make it ideal for extreme working conditions, ensuring that bearings remain protected even in high-stress environments.
Industry Expertise
At Fluid Solutions, we have extensive experience in providing lubrication solutions for the feed mill industry and the broader food and beverage sector. Our team is committed to thoroughly investigating lubrication issues and delivering solutions that not only address the problem but also improve long-term efficiency. Whether you’re dealing with frequent bearing failure, need guidance on roller bearing lubrication, or are looking for lubrication for bearings in extreme environments, our experts are here to help.
Optimize Your Feed Mill with Our High-Performance Lubrication Solutions
Is your feed mill struggling with frequent bearing failures or high grease consumption? Contact Fluid Solutions today to learn how our calcium sulfonate complex greases, like Syntech Food Lube CSCM 2, can enhance your machinery’s performance, reduce downtime, and lower operational costs.
Contact us today at (02) 8370 5928 / (0917) 894 9156 or via email at inquiry@fluidsolutions.com.ph for a consultation on how we can help optimize your feed mill’s lubrication and bearing maintenance.
